4‑Axis Servo Gantry Tyre Automation
A global OEM in the commercial vehicle sector commissioned Frugalhacks Automation to automate the tyre handling and placement process within their wheel assembly line. The manual handling of tyres—each weighing up to 60 kg—posed operational risks, inefficiencies, and ergonomic concerns for operators.
The goal was to implement a 4-axis servo gantry system capable of intelligent pick-and-place of tyres from conveyor to wheel mount, while maintaining high speed, accuracy, and safety.
- Problem Statement
The manual tyre pick-and-place process at a major global OEM’s wheel assembly line posed several challenges:
- High injury risk: Each tyre weighs up to 60 kg, leading to operator fatigue and frequent ergonomic injuries.
- Placement inconsistency: Manual alignment caused misplacements, reducing assembly accuracy.
- Limited cycle time: Human handling could not meet takt time demands, capping throughput.
- No feedback loop: The absence of part presence verification and inspection risked undetected errors.
These issues led to production inefficiencies, compromised quality, and serious safety concerns — calling for a robust automation strategy.
- Our Solution
Frugalhacks Automation designed and implemented a 4‑axis servo gantry tyre automation system, comprising:
- ✅ 2‑axis gantry base (X–Y): Handles high-speed positioning between tyre conveyor and mount station.
- ✅ 2‑axis servo gripper (Z + rotation): Enables vertical lift and angular placement.
- ✅ Vision-guided alignment: Ensures accurate part detection and placement.
- ✅ Siemens PLC + HMI: Offers recipe-based controls, diagnostics, status overrides, and real-time feedback.
The system eliminates manual touchpoints, delivering consistent precision, high throughput, and full motion traceability — all within a compact footprint.
Tools & Technologies Used
Our integrated design aligns with models like SEW‑Eurodrive’s precision gantry systems, achieving fast, efficient and safe tyre pick-and-place operations
Gantry Structure
Fabricated for up to 1 ton load capacity
Motion Control
High-speed servo axes (1 m/s travel speed)
Vision Module
Sensors for tyre detection and alignment
Control System
Siemens PLC with HMI interface and recipe logic
Software Sequences
Custom motion programming, diagnostics, alarms
Safety Integration
Enclosures, soft limits, diagnostics monitoring
- Results & Conclusion
The 4‑axis servo gantry tyre automation system delivered impressive outcomes:
- 35 % faster line speed than prior manual process.
- Zero handling injuries, eliminating heavy-lift ergonomics issues.
- High placement accuracy – no axis bounce or misalignment observed.
- End-to-end traceability – logs gripper actions, cycle times, and posture.
- Greater uptime and scalability – reliable operation in compact space.
With this solution, Frugalhacks empowered the customer to achieve safer, faster, and more reliable operations in heavy vehicle wheel assembly, with full process transparency.
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