Transforming Complex Picking Challenges: Insights from Automation Case Studies

The Customer Challenge

Ace Wire Spring & Form Co., a small to medium-sized business (SMB) situated in Pittsburgh, faces unique challenges in its production process. Engaged in the intricate art of manufacturing custom wire forms, the company employs a detailed 10-step process that is critical to delivering high-quality products. A significant hurdle arose due to a manual operation involving the picking of 5 cm hooks from tangled bins—an arduous and repetitive task that became a major production bottleneck.

The task itself is not just tedious; it resembles extracting a single strand of spaghetti from a messy heap. The hooks often become entangled, complicating the standard bin-picking procedures. This manual aspect slowed down productivity considerably, prompting the need for a modern solution that could streamline this part of the production workflow without compromising quality or safety.

The CapSen Solution

To tackle this pressing issue, CapSen developed a state-of-the-art, fully automated robotic system powered by CapSen PiC technology. The innovative nature of this solution is encapsulated in several key components:

• 3D Vision Algorithms: Implementing advanced algorithms enabled precise pose detection, ensuring the robot could identify each hook’s position accurately.
• CAD-based Geometric Matching: This technique allowed for effective recognition of the variations in hook shapes and sizes, critical for successful picking.
• Machine Learning: A key feature of the system, this component enhances the robotic solution’s capability to identify tangled hooks made from various materials. It learns over time, improving accuracy in detection and handling.

The capabilities of the robotic system went beyond mere detection. It adeptly:

• Isolated Single Hooks: The robot could accurately detangle and pick individual hooks from the pile.
• Cleanly Picked Hooks: Once isolated, it placed each hook directly into a press station, maintaining the workflow’s integrity.
• Motion Planning and Control: The system managed constrained movements effectively, ensuring reliable part delivery to the next stage of production.

Results and Business Impacts

The introduction of this fully automated solution has yielded significant results for Ace Wire Spring & Form Co.:

• Automation of Complex Tasks: A highly intricate, manual operation was successfully automated, freeing up human resources for other essential tasks.
• Increased Speed and Consistency: Automation led to unparalleled speed and reliability during a crucial stage of production, effectively reducing bottlenecks.
• Reduced Reliance on Skilled Labor: While improving safety standards, the company lessened its dependence on skilled manual workers, a vital factor in today’s changing labor market.
• Empowerment through Advanced Solutions: This application of advanced robotics demonstrates how SMBs can leverage technology to tackle complex manufacturing challenges, thereby enhancing operational efficiency.

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