2D Manipulator + Stamping Die(Disc to Lid Blank)

Customized 2D Manipulator + Stamping Die Solution for Indian Client: From Circular Disc Cover Blanking to Finished Product

The long-term reliance on manual labor for round stamping cap production faces three core challenges:

1. Low positioning accuracy due to manual work, resulting in a product defect rate as high as 8% and poor quality stability;

2. Limited production efficiency, insufficient per capita capacity, and difficulty in keeping up with market order growth;

3. Continuously rising labor costs, and high-intensity repetitive work leading to recruitment difficulties and high turnover rates. To overcome production capacity bottlenecks and enhance product competitiveness, customers require a customized round stamping cap solution that is compatible with existing stamping equipment, fully automated, and highly precise (matching the three-stage stamping process).

Customized Solution: Precise Collaboration of a Five-Station 2D Robotic Arm + Dedicated Stamping Die

Addressing the client's core need for "three-stage stamping forming + full-process automation," we have tailored an integrated system of a "five-station 2D robotic arm + dedicated stamping die for round sheet stamping." Key highlights include:

Customized Core Equipment: Five-Station 2D Robotic Arm + Dedicated Stamping Die

The five-station 2D robotic arm is custom-designed to match the three-stage stamping process. It features five dedicated grippers with clearly defined functions, coupled with a high-precision PLC control system and linear motion guides (positioning accuracy up to ±0.02mm), achieving millisecond-level signal linkage with the stamping press and die:

1. Metal sheets are neatly stacked on the automatic feeding table. Sensors detect the material position in real time, providing precise picking signals to the grippers at the feeding station;

2. The 2D robotic arm automatically picks up the metal round sheet and precisely transfers it to the stamping die worktable:

① Feeding station gripper: Equipped with anti-slip and wear-resistant clamps, it accurately grips metal discs and smoothly conveys them to the first stamping station, ensuring accurate initial positioning of the raw material;

②-④ Three-stage stamping station grippers: Corresponding to the disc's "pre-stamping → continuous forming → precise forming," simultaneously completing waste separation. After each of the three core processes, the workpiece is simultaneously transferred to the next station, perfectly matching the stamping cycle with no waiting gaps;

⑤ Unloading station gripper: After the finished product is formed, it quickly grips the disc for stamping and accurately transfers it to the unloading table.

Dedicated stamping molds: Three sets of corresponding mold cavities are customized to optimize the punching clearance and stamping pressure of each process, effectively eliminating burrs and ensuring the curvature and flatness of the discs; the mold structure is precisely adapted to the motion trajectory of the five-station robot, achieving seamless connection between "feeding - three-stage stamping - unloading." 

After the solution was implemented, the client experienced a significant leap in production efficiency and overall benefits:

1. 45% Efficiency Increase: The five-station robotic arm performs three simultaneous stamping operations, nearly doubling single-shift capacity compared to manual operation, easily handling peak order volumes;

2. Quality Leap: Three progressive precision stamping operations combined with precise positioning at five stations reduced the product defect rate from 8% to below 1%, with dimensional accuracy, curvature, and flatness fully meeting international standards;

3. Cost Optimization: 30% reduction in labor input, a 15% decrease in scrap loss, near-zero rework costs, and a return on investment period of only 8 months;

4. Enhanced Stability: Uninterrupted 24-hour continuous operation, clear division of labor at the five stations avoids human error, the production process is traceable, and dependence on manual labor is completely eliminated. 

Customer Feedback:

"This customized solution completely exceeded our expectations! Especially the precise matching of the five-station 2D robotic arm with the three-stage stamping process. It not only perfectly adapts to our existing equipment without requiring significant additional investment, but also completely solves our long-standing problems with quality consistency and efficiency. Now our products are more competitive in the market, and order volume continues to grow. We are very grateful for the professional technical support and customized services!"

Case Highlights Summary:

Precise Customization: Deeply adapted to the customer's three-stage stamping process, a five-station 2D robotic arm was tailor-made, lowering the barrier to equipment modification;

Process Synergy: The robotic arm has clear division of labor across its five stations, working in conjunction with the mold and press signals, ensuring seamless integration of the three-stage stamping process and significantly improving product quality;

Fully Automated: From raw material feeding to finished product unloading, the entire process is unattended, with high efficiency and stable operation;

Value-Oriented: With "efficiency improvement, cost reduction, and quality enhancement" as its core, it quickly realizes a return on investment.