Projects
Ball plugging system for rim painting
Automated feeding with up to 50 insertions per minute
- Industry
- Mobility
- Solution
- Handling / Palletising
The automated ball and plug system handles the precise insertion of masking elements into rims before the painting process. Two robots work in parallel, while feeding technology and cameras ensure fast, positionally accurate supply. After painting, the covers are automatically removed and returned.
Project highlights
- Up to 50 covers per minute
- Two robots for parallel insertion processes
- Four feeding systems with separation
- Camera for position detection
- Endless conveyor for continuous material transport
- Modular design with expansion capability
Application & machining processes
- Automatic feeding via hopper and singulation
- Camera-assisted position detection
- Synchronous insertion of balls or plugs
- Automatic removal after the painting process
- Return of covers to the cycle
Operating & control concept
- PLC control with 15-inch multi-touch HMI
- Display of OEE, shift counters and cycle times
- Type-dependent control logic
- Dynamic process adjustment for product changes
Safety concept
- Protective fence with secured safety door
- Defined robot workspaces
- Enclosed discharge area
- Central Emergency Stop
Result
- High throughput
- Relief from monotonous manual tasks
- Fewer downtimes due to automated feeding
- Consistent quality with changing types
Insights | Process
Conclusion
The system automates the feeding, insertion and return of cover elements, creating a fast, ergonomic process for wheel rim painting.