Example Project: Custom automation system

The engineering challenge

A manufacturer faced a critical bottleneck. Their operation required handling delicate components at high speed while maintaining zero defects. The existing equipment was outdated, couldn't integrate with modern control systems, and the facility space was constrained. The throughput demands were aggressive and the tolerance requirements were tight. TCSC was tasked with designing a system that could solve what seemed impossible within the existing footprint.

The team began by mapping every constraint. The available floor space was 12 feet by 8 feet. Power was limited to 480V three-phase. Components ranged from 2 to 8 pounds and required gentle handling to prevent surface damage. The cycle time target was 45 seconds per unit, meaning the system had to move fast without sacrificing precision. Safety had to be built in from the start, with full compliance to OSHA and ANSI standards.

Design and integration

The 3D design process started with a complete CAD model of the facility layout. Every dimension was verified on-site. The team modeled multiple robotic configurations before selecting the ABB IRB 6700, which offered the reach, speed, and payload capacity needed. Custom end-of-arm tooling was designed specifically for this application, with a pneumatic gripper engineered to handle the component geometry without damage.

Vision system integration was critical to the solution. A Cognex camera was mounted above the assembly point to inspect each component before it entered the handling sequence. The vision software was trained to detect surface defects, dimensional variations, and orientation errors. Any part that failed inspection was automatically diverted to a reject bin, ensuring only good parts moved forward.

The PLC control system was built around a Siemens S7-1200 controller. The program logic handled the exact sequence of operations, managing robot movements, gripper actuation, vision triggers, and conveyor timing. Distributed I/O modules were placed at key points in the system to provide real-time feedback on part position, gripper status, and safety sensor inputs. The entire control architecture was designed for reliability and ease of troubleshooting.

System architecture

The machine operates as an integrated cell with five main components working in concert. Parts arrive on an input conveyor and are positioned at the load station. The robot picks the part and moves it to the inspection point where the vision system captures images and analyzes them. If the part passes inspection, the robot transfers it to the assembly station where it is oriented and placed into the fixture. The system then signals the next process downstream and returns to pick the next part.

All movements are synchronized through the PLC. The robot doesn't move until the vision system confirms the previous part has been inspected. The conveyor doesn't advance until the robot has cleared the load station. The downstream process doesn't start until the robot has released the part. This orchestration prevents collisions, ensures parts flow smoothly, and maintains the 45-second cycle time consistently.

Safety is embedded throughout the design. The robot operates within a guarded enclosure with interlocked gates. Emergency stop buttons are positioned at multiple points. Light curtains monitor the load and unload stations. Pressure relief valves protect the pneumatic system. All electrical connections are redundant where required. The system was tested to ISO 13849-1 PLd standards before leaving the shop.

Build and commissioning

Construction took eight weeks from start to finish. The structural frame was fabricated from welded steel and finished with a powder coat. All electrical components were mounted on a control panel with clearly labeled terminals and circuit protection. Pneumatic lines were run with color-coded tubing and labeled at every connection point. Cable management was organized to prevent damage and simplify future maintenance.

Once assembled, the system underwent rigorous testing. Every movement was verified for speed and accuracy. The vision system was calibrated and tested with sample parts. The PLC program was run through simulation before being loaded into the controller. Safety systems were tested to confirm they responded correctly to fault conditions. The entire system ran for 48 hours continuously to verify reliability before being shipped.

Commissioning at the customer site took three days. The system was positioned, leveled, and connected to the facility's power and compressed air systems. The PLC was programmed with the final parameters specific to the customer's environment. Operators were trained on how to load parts, monitor the system, and respond to alarms. The first 100 parts were run under supervision to confirm everything was working as designed.

Performance in operation

The system has been running for over two years now. The 45-second cycle time is consistently achieved, sometimes beating it by a second or two. The vision system catches defects that would have slipped through manual inspection. The reject rate dropped from 3.2% to 0.4%. Production increased from 60 units per shift to 192 units per shift. The facility went from needing four operators on this line to needing one operator to monitor and load parts.

Downtime has been minimal. The system runs five days a week, 16 hours a day. Maintenance is limited to weekly checks of the gripper wear pads and monthly cleaning of the vision camera lens. The customer has not experienced a single unplanned shutdown. When a component needs replacement, TCSC provides the part and remote guidance for installation. The system was designed to be maintained by the customer's own technicians, and it has proven to be straightforward to service.

The numbers tell the story. The 18-month ROI timeline was met. The 47% efficiency gain was realized in the first month and has held steady. The 3.2x production increase has allowed the facility to take on new business without expanding headcount. The system paid for itself and continues to generate value every single day it runs. This is what precision engineering and careful integration deliver when they meet real industrial demand.