3D Bin Picking for Automated Stud Welding of Stove Gas Caps

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 A stove gas cap manufacturer needed an automated machine capable of running a progressive stud welding process “lights out” for an entire shift or longer.  The goal: allow an operator to load part feeders, start the machine, and walk away for 8+ hours of uninterrupted runtime before replenishing parts.

MS Automation delivered a custom system designed for efficiency and precision. Using cutting-edge Keyence 3D vision guidance, a 6-axis Fanuc robot accurately picks individual stamped caps from dunnage holding thousands of loose pieces. Each cap is placed into a centering fixture capable of handling four different diameters with pinpoint accuracy.

A Fanuc SCARA robot introduces unfinished caps to the welding process and removes finished products. The welding process itself is powered by an indexing dial table that moves caps through a progressive stud welding operation. Six dedicated feeder bowls blow-feed studs to four weld guns, enabling seamless completion of multiple product recipes without manual intervention.

To ensure quality, a final inspection system identifies defective parts, which are automatically segregated during packout.

Part changeovers between cap sizes are fast and efficient, thanks to quick-release dial nests and forklift-friendly dunnage swapping.

This innovative solution exemplifies MS Automation’s commitment to creating advanced systems that meet complex manufacturing challenges with precision and reliability.