Material Handling Automation And Robotics

Product Details:

At Master Automation & Robotics, we specialise in designing and manufacturing of Engine Assembly And Testing Line Machine  We have a strong experience in handling diverse set of components and assemblies ranging from 5 kg to 32 tons. Superior engineering technology and customer satisfaction have been at the heart of our all solutions and products. We deliver solutions of the highest international standards at economical prices.

We are proud of our strong customer references in automotive, white goods, farm & construction equipment, and general & heavy engineering. Our customer base in industries such as food & pharma, railways & metros and defence is growing very fast.

Our expertise covers automation solutions for different types of assembly applications. An automated assembly line uses a wide array of standardised solutions, including robotic assembly, and ensures assembly line balancing. Our decades of experience in assembly automation allows us to find innovative solutions to address long standing bottlenecks and production challenges.

The design of our typical assembly line automation system is customised to the production strategy and number of product variants. Irrespective of the complexity the assembly line is designed to be highly efficient, flexible and cost effective.

Assembly Line Production

Automated assembly ensures high throughput, efficiency and quality. Our assembly line is designed and built to meet the high volume, precision and quality requirement.

We use assembly conveyor systems such as roller conveyors, chain conveyors, slat conveyors, overhead conveyors, and belt conveyors. The assembly process is optimised through the use of intelligent assembly automation systems such as gantry robot, electrified monorail system (EMS), and automated guided vehicles (AGVs).

Assembly Line Balancing

The most important business challenge for manufacturing companies is how to increase the flexibility and speed of production while keeping costs down. One of the key technologies is assembly line balancing. Balancing an assembly line is a procedure in which tasks are distributed evenly to each assembly station in the line so that each workstation has the same amount of the work.

 

It is very important to balance the workload of the operator at every station and to reduce the operator idle This means increasing the station utilisation to the maximum.  A well-balanced workstation reduces waste, increase utilisation and throughput, while reducing faults and rejections. It also allows the company to reduce the price of their product through the decrease in production cost of the unit.

Assembly Line Automation

Automation of the assembly process guarantees not only the productivity, but also the product quality. It is designed and built to meet the high volume, precision and quality requirement.

• Full integration with line tooling and testing equipment
• Customised, modular and flexible solutions based on the application
• Advanced automation technology using mechatronics
• Ergonomic & operator friendly design
• Safety interlocks and compliance to safety standards
• Production planning and control through central PC / SCADA / IoT

Product Details:

Where the volume, precision and quality requirement is high, automated assembly and testing lines are a must. Our automated lines guarantee not only the productivity, but also the product quality.

 

Full integration with line tooling & testing equipment  Customized, modular & flexible solutions based on the application Advanced automation technology using mechatronics  Ergonomic & operator friendly design  Safety interlocks & compliance to safety standards  Production planning and control through central PC / SCADA / IoT

Product Details:

What is an Electrified Monorail System?

The effectiveness of any automation system depends entirely on the quality of its underlying electrical, mechanical and control engineering. Our Electrified Monorail System (EMS) are highly flexible and intelligent conveying systems suitable for various applications such as assembly, painting, testing and transfer. It is built to ensure that product is always moved in the safest, quietest, cleanest and most efficient way possible.

An EMS system is an electric monorail system that carries parts individually to each workstation. It is an overhead rail-bound means of conveyance with individually driven carriers, which move independently on the rail system. The track consists of joined section rails and integrated busbars, which can be extended to the desired length. Branch points can be implemented on the line with the aid of switch points. The vehicles are supplied with power and control signal via collector wires on the carrier rail.

The motorised carriers with on-board control travel independently while coordinating with the other carriers and the overall system. The use of an EMS is the obvious choice when it is necessary to interconnect large spatial distances or even different buildings logistically.

The EMS system is completely modular. The travel loops are designed to meet the production & layout requirement. The track switches and elevators offer lot of flexibility in terms of the layout and component movement.

Special Features of an Electrified Monorail System

• Customised, modular & flexible design based on the application
• Rapid & precise point to point movement
• Clean, quiet & maintenance free operation
• Perfect integration & safety interlocks with related equipment
• High speed transfer over long distances
• Carriers with on-board intelligence & programmable controls
• Suitable for components with big size, high weight & critical geometry
• Ergonomic & safe operation

Main Applications of on Electrified Monorail System

• Assembly Line
• Paint Shop
• Body Shop
• Warehouse
• Overhead Transfer

An Electrified Monorail System (EMS) is a highly flexible and intelligent conveying system. The motorised carriers with on-board control travel independently while coordinating with the other carriers and the overall system. The use of an electric monorail is the obvious choice if it is necessary to interconnect large spatial distances or even different buildings logistically. Unlike stationary conveyor systems (e.g. roller conveyors or carrier chain conveyor), the electric monorail system is far more efficient and fast.  

Product Details:

At Master Automation & Robotics, we build Pick And Place Gantry System for various applications. These applications include machine loading and unloading, part transfer, palletising and changing component orientation. The gantry robot or the pick and place robot reduce handling damages, operator fatigue and the space requirement, while increasing the productivity and efficiency.

The following special features characterise our gantry robots and pick and place machines:

• High speed transfer using servo control where required
• Suitable for long travel & multiple stations
• Perfect gripping of big & heavy components with critical geometry
• Precise component positioning, orientation & placement
• Customized, modular & flexible solutions based on the application
• Perfect integration & safety interlocks with related equipment

With the new industrial revolution (industry 4.0) under way, there is a need to automate/digitise even the simplest processes to keep companies competitive, efficient and secure. Our automated gantry and pick and place systems helps achieve these goals. The benefits of using an automated pick and place machine go far beyond increase in productivity.

Gantry Robot
The gantry robot is a 3-axis rectangular plane Cartesian coordinate robot, which performs pick and place tasks and also detects the obstacles in its path. The robot runs on a machined beam with defined stations. It typically has a rack and pinion arrangement in X and Y direction. While working in X direction, the rack will be fixed and pinion will be moving. For the Y direction rack will be moving and pinion will be stationary. The control system ensures the speed and stopping accuracy.

The gantry robot plays an important role in replacing manual work, especially in heavy manufacturing, hazardous environment and high-speed production. It helps achieve production speed, efficiency and accuracy, which is not possible through manual operations. The gantry robot also adds lot of flexibility to the production process. Moreover, it is a completely modular system that can be scaled up in the future to meet higher production needs.

Pick and Place Machine
Manual picking and placing is inefficient and prone to damage. Compared to a pick and place machine, the manual process is slow, inflexible and unsafe. A pick and place machine uses automation making the process much more reliable and efficient.
The pick and place machine is designed based on the required accuracy, weight of the object, metal and non-metal detection, obstacle detection and overall cost. A programmable logic controller (PLC) or an industrial PC controls the entire system. Sometimes a pick and place robot is used to meeting the application requirement.

Product Details:

A modern day machine shop is distinguished by its automated loading & unloading system. The Machine Shop Handling Systems is important for reducing the handling damages, operator fatigue and the space requirement, while increasing the machine utilisation and shop throughput. These systems are built to handle the parts and components on machine tools and between machines.

Our machine shop handling systems ensure:

• High-speed overhead gantry movement & continuous operation
• Perfect gripping of big size, heavy components with critical geometry
• Precise component positioning, orientation & placement
• Flexibility through customised and modular solutions
• Perfect integration and safety interlocking with related equipment

With the new industrial revolution (industry 4.0) under way, there is a need to automate/digitise even the simplest machine shop processes. This is required to keep the machine shop competitive, efficient and secure. Our automated material handling system helps achieve these goals. Thus the benefits of our machine shop part handling systems go far beyond increase in productivity.

The gantry robot is a 3-axis rectangular plane Cartesian coordinate robot, which performs pick and place tasks and also detects the obstacles in its path. The robot runs on a machined beam with defined stations. It typically has a rack and pinion arrangement in X and Y direction. While working in X direction, the rack will be fixed and pinion will be moving. For the Y direction rack will be moving and pinion will be stationary. The control system ensures the speed and stopping accuracy.

 

The gantry robot plays an important role in replacing manual work, especially in heavy manufacturing, hazardous environment and high-speed production. It helps achieve production speed, efficiency and accuracy, which is not possible through manual operations in a machine shop. The gantry robot also adds lot of flexibility to the production process. Moreover, it is a completely modular system that can be scaled up in the future to meet higher production needs.

The auto loading and unloading machine provide users with benefits including higher throughput, improved process flow, reduced product damage and consistent run speeds with no breaks, shift changes or rehires. Increasingly, machine shops are looking for ways to automate their complete production facilities with installing auto loading and unloading systems at every workstation.

Manual picking and placing is inefficient and prone to damage. Compared to an automated loading and unloading machine, the manual process is slow, inflexible and unsafe. A loading and unloading machine uses automation making the process much more reliable and efficient.

The loading and unloading machine is designed based on the required accuracy, weight of the object, metal and non-metal detection, obstacle detection and overall cost. A programmable logic controller (PLC) or an industrial PC controls the entire system. Sometimes a pick and place robot is used to meeting the application requirement.

Product Details:

Automated Storage And Retrieval System for Warehouse Automation

A high movement warehouse with many storage locations requires a Automated Storage and Retrieval System (ASRS). Our warehouse automation systems are designed not only to save space, but also for improving the efficiency and optimising the costs. In an automated warehouse, the ASRS system is used to get the right parts, packages, pallets, fixtures, and tools to the right place at the right time. For efficient and fast operation, in an automated warehouse, a high performance storage and retrieval system with material transportation is required.

Our Automated Storage and Retrieval Systems (ASRS):

• Optimise the available space and storage requirement
• Provide accurate inventory information with age
• Manage storage and retrieval at high-speed and high-accuracy
• Eliminate damages from manual handling and dependency on labor
• Run on automation software developed by in-house experts
• Integrate with ERP/MIS system for planning and inventory management

An Automated Storage and Retrieval System (ASRS) typically consists of racking system for storage, storing and retrieving machine, a controlling system and a inventory/order management software. They are highly suitable for automotive industry, chemical industry, food industry, textile industry, pharmacy industry, transportation industry, and warehouse automation.

Benefits of ASRS Systems in an Automated Warehouse

• Compact Footprint– ASRS technologies provide highly dense storage and can save up to 85% of floor space occupied by storage. Improve warehouse utilisation, reduce storage area, and save land investment
• Reduced Labor Requirements– ASRS systems require much less labor to operate when compared to manual operation. They allow users to easily and quickly retrieve items reducing the labor costs and dependency.
• Improved Pick Accuracy– Automated ASRS systems use pick to light technology to direct the operator to the exact location of the stored item, achieving 99.9% pick accuracy rates. They improve the accuracy and efficiency of inventory with automated/semi-automated identification.
• Increased Throughput – ASRS enables faster pick up to keep up with customer demand. It is easy to optimise the overall system, improve production efficiency and manage the logistics.
• Greater Inventory Control– ASRS solutions manage inventory so you always know what you have and more importantly – where it is and how old it is. They facilitate the formation of advanced logistics systems and improve the production management level of enterprises.
• Improved Safety & Ergonomics– ASRS technologies create a safe and ergonomic working environment for employees. Many safety interlocks are built-in to unsure accident-free operation

Product Details:

Material Handling Capacity Depend Upon Application.  

We offer our products under the Innovative Brand name in the market. Our quality controllers, with their stringent quality check, ensure flawless range.

Product Details:

Robotic Welding System refers to the use of equipment for welding that run automatically without the need for an operator. The welding process is controlled by computer programs. This process improves the welding quality and production efficiency. With automation, the quality, speed and reliability is very high. Hence, the welding automation systems are finding wide use in industry, especially for mass production.

Our welding automation systems are designed to meet the welding quality and cycle time requirement.

• Guaranteed production and welding quality
• Fully integrated with welding equipment and robots
• Flexible system able to handle variety of models
• Precise component positioning, orientation and clamping
• Integrated end-to-end handing solution
• Close partnership with experts in field of welding

As the name suggests, Robotic Welding systems use a robot for welding. The robot holds the torch and is programmed to move it along the welding path. The robot is able to reach into inaccessible areas and perform critical welding task. Moreover, the welding is done at very high speeds with equally high precision. Furthermore, the robot can be taught and programmed with different welding tasks and hence provides a very high level of flexibility.

With their positioning accuracy and welding parameter control, they eliminate the welding inconsistencies and errors. The production efficiency and throughput cannot be matched with manual process. Also, the uses of robots make the welding process extremely safe and accident-free.

At Master Automation & Robotics, we specialise in welding automation systems where the material handling is critical. High accuracy handling system is required for precise positioning and accuracy of the parts. The positioning accuracy of the components is extremely critical for the quality of the weld. The handling system also eliminates operator fatigue and improves the overall safety of the welding operation.

 

An overhead pick and place gantry type of handling system is very common for part loading and unloading. It loads the parts to be welded on welding fixture or workstation at the right position with the right orientation. After the welding is over, it picks up the parts and transfers them to the next station. The handling system integrates perfectly with the welding fixture, robots and related equipment.

Product Details:

Material Handling Capacity Depend Upon Application.  

We offer our products under the Innovative Brand name in the market. Our quality controllers, with their stringent quality check, ensure flawless range.

Product Details:

Material Handling Capacity Depend Upon Application.  

We offer our products under the Innovative Brand name in the market. Our quality controllers, with their stringent quality check, ensure flawless range.

Product Details:

In an I-Beam Conveyor System the overhead conveyer chain rides on an I-Beam rail. These conveyors are highly rugged and cost-effective. They are made from heavy duty forged chain and trolleys. The trolleys can carry heavy parts over long distances.

• High quality drop forged rivet less chain with high strength-to-weight ratio
• High strength ribbed steel brackets attached to the wheels
• Protection against anti-runback and reverse run
• Special lubrication system for rollers
• Suitable for temperatures up to 260 degree Celsius
• Modular design which is easy to install and configure
• Quiet and clean operation, easy to Maintain 

Product Details:

Power And Free Conveyor System are one of the most flexible overhead conveying solutions. This paint shop conveyor uses two tracks. In one track, the power track, the chain is continuously running. In the other track, the free track, the chain pushes the trolleys forward with pusher mechanisms (known as “pusher dogs”) mounted at regular intervals. The power and free conveyor allows for:

• Buffer and accumulation zones by queuing of components one behind the other
• Bias banking for efficient storage and space utilisation
• Automatic routing of components for module wise segregation, rejection, dedicated storage, etc.
• Speed changes based on the process requirements
• Drop and rises depending on the application and ergonomic requirement

 

Product Details:

An Overhead Conveyor System , as the name suggests, is a conveyor system that moves material overhead. It utilises the typically unused overhead space in a factory or warehouse helping to save on valuable floor space. An overhead conveyor can move parts in a straight path, around a curve and along a vertical rise/fall. Overhead conveyors use a single track or rail. They can be manually pushed, motorised or power and free. They use very little energy in moving the parts over long paths. It is a very versatile conveying solution and can be used for various applications.

• High efficiency and very low energy consumption
• Quiet and clean working
• Modular allowing for easy layout changes
• Short radius curves for navigating tight spaces
• Versatile application – continuous, stop-&-go, power & free

An enclosed track overhead conveyor has a chain running in a closed track. The chain is bi-planar with horizontal and vertical rollers. The components hang from the chain load links and supported on the track by the vertical roller bearings. Horizontal roller bearings in the chain guide it along the curves. The closed track protects the chain from dust and other contaminants ensuring continuous trouble free operation.

Some special characteristics of our Enclosed Track Overhead Conveyor are:

• High strength chain formed using forged steel links
• Enclosed track for protection against dust and contaminants
• Extremely compact layouts possible – turning radius 305 mm
• Suitable for temperatures up to 260 degree Celsius
• Mist-type lubrication system – PLC controlled
• Track manufactured from cold rolled steel
• Modular design which is easy to install and configure
• Quiet and clean operation, easy to maintain

Product Details:

we manufacture Paint Shop Conveyor System  and handling systems that meet the specific surface treatment and painting needs. Our automated conveying solutions are ideally suited for the paint shop environment and automation.

Component conveying system used in the paint shop is critical for the final finish quality and throughput. Our automated conveying solutions enable high productivity, perfect finish quality and cost efficiency. Freshly painted parts are delicate and fragile; they require special attention for their handling. Everything must be perfectly controlled as painting is done while parts are in motion. Any vibrations or speed inconsistencies compromise the final result. Pre-treatment process, painting and curing cycle times must be strictly achieved.

With our experience and expertise, we provide ideal paint shop conveyor and material handling solutions for:

• Powder Coating plant
• Pre Treatment plant
• CED Coating plant
• Phosphating plant
• Wet Spray Painting plant

Product Details:

Dip Type Multi Tank Transporter System is used for the automated handling of components in a multi-tank dip type process. The system is programmed to pick and move the components to the next process tank after specified time. The dip timings are precisely controlled and matched with the required process timings. The transporter system does this without any manual intervention. The system is used industry-wide for 7 tank pre treatment process and ed coating. They find application for painting in CED coating plant, Pre treatment plant and phosphating plant. We have designed transporter system for components with span up to 16 m 

Advantages of Dip Type Transporter Systems

In a dip type transporter system, multiple wagons are used to meet the required process and cycle times. The system is fully automatic removing manual intervention and increasing the productivity and efficiency. The exact process time in each time is accurately met ensuring. the final quality. The transporter system is highly suitable for heavy and big jobs and improves overall safety and work environment.

• Suitable for long travel & multiple stations
• Multi-wagon systems with high throughput
• Compatible with CED & other coating processes
• Perfect integration & safety interlocks with related equipment
• Highly reliable design, easy to operate & maintain
• Customised, flexible & modular solution based on  the application

Dip Type Transporter System – Areas of Application Pre treatment Plant / Phosphating Plant

Pretreatment is a fundamental prerequisite for any high quality coating. Wet or dry pretreatment, depends on the material to be coated. A pretreatment plant or a phosphating plant is customised according to the process requirements and cycle time. The transporter system is programmed based on the required timing in each tank and overall cycle time. It ensures that the component surface is perfectly ready for coating/painting.

For further information see: Pretreatment for Painting – Products Finishing

CED Coating Plant

Cathodic Electro Deposition (CED) is one of the most advanced and environment friendly water based coating process done on the metal components.  Combination of dip and spray ensures that the paint reaches at every corner of component. CED coating is most widely used coating process in automotive industry. The transporter system enables perfect control on the process and cycle time for high quality coating at minimal cost.

Plating Plant / Electroplating Plant

A Dip Type Transporter System plays an important role in modern plating plants for highly efficient and operator friendly production. Electroplating involves the deposition of a thin protective metallic layer onto a prepared surface of metal, using electrochemical processes. Being specialised in material handling systems, we offer wide range of transporter systems for plating application. The transporter wagons provide the means for mechanised movements of parts through the tanks. They control the process time accurately for high quality plating at lowest cost.