3 Axis Servo System for Planetary Gearbox Assembly Line
Frugalhacks Automation, based in India, India, was tasked with automating a planetary gearbox assembly line for a global off-highway mining truck manufacturer. The project aimed to address challenges such as assembly inaccuracies, ergonomic issues, torque inconsistencies, and production bottlenecks.
- Problem Statement
- Assembly Inaccuracy: Manual alignment of complex multi-part assemblies led to inconsistencies.
- Ergonomic Issues: Handling heavy gears and housings manually posed safety risks.
- Torque Inconsistency: Manual torqueing resulted in uneven preload and inconsistent gear performance.
- Line Bottlenecks: Uncoordinated loading, tightening, and pressing processes caused delays.
- Lack of Real-Time Data: Absence of logging or quality traceability hindered performance monitoring.
- Our Solution
Frugalhacks developed an integrated 3-axis servo-driven system incorporating:
- 3-Axis Servo Motion System: Enabled precise handling of gear housing and carrier.
- 12-Axis Linear Track: Facilitated movement of large gearbox components between stations.
- Auto Vision System: Ensured accurate alignment and position validation before pressing.
- Robotic Bolt Pick & Place: Automated consistent bolting sequences.
- Trunnion System: Rotated and stabilized gear housings for ergonomic assembly.
- 50-Ton Hydraulic Stud Press: Applied controlled force for final pressing operations.
- Siemens PLC/HMI: Unified system logic, alarms, diagnostics, and data logging.
Tools & Technologies Used
Servo Motors & Gearboxes
Provided precision motion control.
Robotic Arms
Automated bolt handling and placement.
Vision Systems
Ensured component alignment and quality checks.
Hydraulic Presses
Delivered consistent pressing force.
PLC & HMI Systems
Enabled centralized control and monitoring.
- Results & Conclusion
- 50% Reduction in Cycle Time: Coordinated operations minimized delays.
- Enhanced Assembly Accuracy: System-monitored torque and load ensured consistent quality.
- Improved Operator Safety: Eliminated manual handling of heavy parts.
- 24/7 Operational Readiness: System designed for continuous operation.
- Comprehensive Traceability: All assemblies logged with detailed data.
Frugalhacks’ automation solution significantly improved the efficiency and reliability of the planetary gearbox assembly process, setting a new standard in the heavy equipment manufacturing industry.
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