Robotic Cell for Gear Handling

For DAF Trucks in the Netherlands, we designed a fully automated robotic cell for gear handling. The workstation integrates multiple stations within the heat treatment and gear hardening process into a single automated system.

The project addresses the handling of heavy gears in a demanding production environment, where parts exiting the furnace exceed 500 °C. The automation ensures a continuous material flow throughout the heat treatment process, minimizes manual intervention, and provides full traceability of every part through product identification codes.

The robotic cell automatically unloads parts from the incoming pallets, identifies the part type to ensure safe gripping by the robot gripper, and transfers the gears between individual process stations while handling components at elevated temperatures. Finished gears are then precisely stacked onto outgoing pallets in a predefined pattern.

Main Technologies

• robot with dedicated gripper
• infeed and outfeed conveyor system
• product identification using DMC (Data Matrix) codes
• integration of third-party technologies into the cell control system
• stations for manual inspection
• station for removal of process fluids from gears
• safety fencing and controlled access to the robotic cell
  
  
  

Scope of Supply by ICE

• mechanical and electrical design
• PLC software development and HMI visualization
• development of the part type identification system
• supply of mechanical and electrical components
• installation and testing
• CE certification of the machinery
• commissioning and operator training