The Challenge
Replacing Multiple Manual and Legacy Processes with One Automated System
The customer’s process required multiple steps including hole creation, notching, stamping, and cutting to length. These operations were previously handled through separate processes, creating inefficiencies in material flow and process control.
Key challenges included:
• Processing aluminum extrusions ranging from 48 inches to 144 inches in length
• Accommodating multiple extrusion profiles and widths
• Maintaining consistent positioning for cutting and stamping operations
• Replacing punch and shearing operations with laser cutting
• Managing part transfer between multiple process stages
The system also needed to support different part configurations, including standard and plug-in models with varying hole patterns and notch requirements.
The Solution
Fully Integrated Robotic Cell with Laser Cutting, Saw Cutting, and Gantry Handling
MWES engineered a multi-station automated cell that integrates material handling, laser processing, stamping, and cutting into one system.
Infeed and Material Handling
Operators load raw aluminum extrusions onto an infeed conveyor. A gantry pick-and-place system transfers material into the laser processing station, positioning parts on a servo-driven feeder for precise movement through the system.
Laser Cutting Station
An ABB robotic system equipped with a laser cutting head performs all hole cutting operations. The system replaces traditional punching by cutting circular, square, and rectangular holes, as well as notches, directly into the material. A servo feeder advances the part in controlled increments to position each cut accurately.
Transfer and Secondary Processing
After laser processing, a second gantry transfers the material to the next stage. A servo-controlled feeder positions the part for pin stamping and saw cutting operations.
Saw Cutting and Pin Stamping
An ABB robotic system with a saw spindle cuts parts to final length and performs notch cuts when required. A pin stamping unit marks part information prior to final cutting. A second robot handles finished parts and drop material, placing completed components onto an outfeed conveyor.
Integrated Controls and System Coordination
The system utilizes ABB robots for motion, an Allen-Bradley PLC for control, and a PC-based interface for job management and cut optimization. Each station is synchronized to maintain consistent material flow and process control across the cell.
The Results
Streamlined Processing with Integrated Cutting and Material Flow
The automated housing cell provided the customer with:
• A single system replacing punching, cutting, and handling operations
• Integrated laser cutting for flexible hole patterns and part configurations
• Coordinated material flow from raw extrusion to finished part
• Automated transfer between processing stages
• Structured validation through FAT and on-site acceptance testing
The system was designed with an estimated cycle time of approximately 60 seconds per part, depending on configuration, and an expected OEE range of 80-85% under defined operating conditions .
By consolidating multiple processes into one automated cell, MWES delivered a solution that improves process control, supports production flexibility, and enables consistent handling of aluminum extrusion components.
