Client Needs & Project Goals

A manufacturing client required an automated solution to handle the manipulation, inspection, and packaging of machined components. The core needs of the project included:

  • Automated retrieval of raw parts from gitterbox,
  • Visual inspection for quality control for two different types of components (raw and machined)
  • Automated sorting and placement of good parts into specific boxes,
  • Reliable system operation with built-in rework and error handling.

The objective was to streamline the handling process, reduce operator involvement, and maintain 100% quality assurance in a high-throughput environment.

“We needed flexibility and consistency — Iskra PRO delivered both. Their system helped us scale efficiently while improving quality at the same time.”

Step-by-Step Assembly Process

The solution integrates advanced robotics, vision systems, and smart mechanical design. The system is divided into four functional areas:

1. Raw Part Loading

  • An operator delivers a gitterbox with raw parts to the station with floor-mounted steel frame.
  • Presence sensor ensure accurate placement.
  • Due to camera-based robotic guidance (bin picking) no precise orientation of parts is required.

2. Empty Blister Tray Loading

  • Empty boxes are placed upside-down by the operator onto a second pallet station.
  • The system uses pneumatic clamps and side pushers to align the pallet.
  • A roller track ensures smooth lateral positioning.

3. Robotic Handling of Raw Parts & Blisters

A 6-axis robot handles both raw parts and blister trays.
Robot picks raw parts using a camera-guided gripper and places them onto a conveyor belt.
When needed, robot switches grippers to handle blister trays:

  • Boxes are first aligned at a centering station,
  • Then rotated and repositioned for final placement on the pallet for end packaging.

The robot also has a fallback station for incorrectly picked parts and includes a reference piece for recalibration.

4. Vision Inspection

Parts move along a conveyor into the vision inspection cell.
Depending on part type:

  • Machined parts are picked via vacuum,
  • Raw parts are picked using a three-finger gripper.

Inside the cell, parts are rotated and moved between control points:

  • Each side is visually inspected with 3 cameras and 2 profile scanners,
  • The part is flipped mid-cycle for full surface inspection.

After inspection:

      • Good parts are placed into boxes by the second robot,
      • Rejected parts are placed into a separate tray.

Results & Benefits

With this integrated system, the client achieved:

  • Error-free handling through vision-guided robotics,
  • Parallel robotic processes for improved efficiency,
  • Full in-line quality control,
  • Manual rework option without interrupting production.

Summary

  • Fully automated inspection and packaging of machined components
  • Dual-robot solution for simultaneous handling and inspection
  • Vision cell ensures 100% quality assurance
  • Built-in error detection and recovery
  • Fast, flexible production suited for different part types
Automated Sorting and Inspection Station
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