Automotive Engine Block Machining Robot Quick Change Tool Plate Application Case Study

This case study details the application of the Quick-Change Tool Plate in an automated production line for automotive engine blocks. By enabling a single industrial robot to rapidly switch between different end-effectors (e.g., two-finger grippers, vacuum cups), multiple processes were accomplished, including handling raw blanks, machine tool loading/unloading, cleaning/inspection, and finished product handling, significantly improving production efficiency and flexibility.

1. Raw Blank Handling: The robot, initially equipped with a high-capacity two-finger gripper (connected via the Quick-Change Tool Plate's Robot Side), moves to the raw material area. The gripper adapts its grip force and angle to the engine block blank's shape, securely lifting the heavy blank (weighing up to 500kg). It then precisely places the blank onto a conveyor belt feeding the machining center.

2. Machine Tool Loading/Unloading: Once the blank arrives at the machining center, the robot moves to the tool rack. The Robot Side of the Quick-Change Tool Plate disengages from the current gripper's Tool Side and quickly couples and locks with another Tool Side on the rack (connected to a specialized fixture, like a three-finger electric gripper or a non-marring holder for machined surfaces) in less than 3 seconds. Using the new electric gripper, the robot, with ±0.02mm repeatable positioning accuracy, extracts a block that has completed a machining operation from the center. It then loads the new blank into the machining center for fixing. The force control capability of the electric gripper ensures zero damage to the precision-machined surface.

3. Cleaning & Inspection Station: After machining, the block is conveyed to a cleaning and inspection station. The robot can perform another quick tool change to mount specialized tools like a cleaning nozzle or a vision inspection sensor for blowing off chips and checking critical dimensions.

4. Finished Product Handling: Finally, the robot switches back to the high-capacity two-finger gripper, picks up the inspected and approved finished engine block from the inspection station, and places it onto the finished goods stacking area or assembly line conveyor. Throughout the process, the high precision of the Quick-Change Tool Plate ensures accurate robot trajectory execution after each tool change. Its high load capacity and self-locking feature guarantee safety and reliability during heavy-load handling.

• Enhanced Efficiency: Enabled a single robot to perform multiple tasks, reducing the number of robots and capital investment on the line. Rapid tool changes drastically reduced changeover time between processes, accelerating production cycle time. The automotive parts manufacturer achieved a productivity increase of approximately 40%.

• Improved Flexibility: Provided the adaptability to accommodate production schedule changes and mixed-line production of different engine block models, meeting the demands of flexible "high-mix, low-volume" manufacturing.

• Guaranteed Quality & Safety: High-precision grasping and placement prevented scratches and damage to workpiece surfaces, improving product quality. Automated handling and the secure locking mechanism reduced safety risks associated with manual operation.