ESA were tasked with upgrading a manual assembly station to a fully automated process, improving efficiency while maintaining safe operation.

The Challenge

The existing station relied on manual processes for key assembly steps, limiting productivity and increasing cycle times.

The client required a fully automated solution to:

• Load bearings automatically
• Mesh gears onto the input shaft assembly
• Remove synchro assembly clamps
• Maintain flexibility to revert to manual operation if required

The goal was to significantly reduce cycle time while ensuring safe integration into the existing production line.

Our Approach

ESA designed and implemented a robotic solution using an ABB IRB1600 robot, equipped with a custom multi-purpose gripper.

The system was developed to handle multiple tasks within a single automated cycle, including:

• Removing and storing synchro assembly clamps
• Picking and loading gears with precise spline alignment
• Automatically loading bearings into press tooling
• Handling component transfer between station positions

To support automation, the assembly line pallets were modified to allow consistent part presentation for robotic pickup.

Safety & Integration

Introducing robotics into the station required a complete review of existing safety measures.

ESA carried out a full risk assessment and implemented:

• New perimeter guarding around the robotic cell
• Repositioned light guarding for operator access
• Safety monitoring to ensure the robot remained in a safe parked position during manual override
• Interlocked access points for controlled entry

The system was designed to safely switch between automatic and manual operation when required.

Process Improvements

Through detailed process analysis and FMEA studies, ESA identified opportunities to streamline the operation.

A key improvement was the development of a multi-purpose gripper, which:

• Reduced the need for multiple tools
• Minimized robot movement
• Improved overall efficiency

Additional handling systems were introduced to position bearing stacks for accurate and repeatable placement.