Delta’s machine vision robotic solution helps metal LS Build precise, quick, and flexible assembly lines

Metal hardware is a common component of our daily lives. During production it becomes durable and detailed through casting, forging, polishing, and assembly procedures. However, with rising demand and the trend for small-volume large-variety production, manufacturers have started to seek new solutions using smart manufacturing that features high speed, high precision, and flexibility to meet market growth.

The Bulgarian hardware manufacturer, Metal LS, was looking for solutions. As one of the world's biggest manufacturers of cylinder locking systems and hardware handles, Metal LS started to plan a new automated assembly for door locks in 2019. Considering that the original systems were too large for the new production site, Metal LS needed a solution with a compact design that could assemble 10 to 14 locks per minute. Apart from the size and speed, it was equally important that the solution met local standards of high precision and flexibility to retool for different product types. After a comprehensive evaluation, Metal LS opted for Delta's robotic system. The co-developed customized workstation integrated Delta's PLC, HMI, servo system, industrial robot, and machine vision system, which completely fulfilled the requirements for speed, precision, and flexibility. 

Metal LS adopted Delta’s highly integrated one-stop Machine Vision Robotic Solution for quick adjustments and to accelerate implementation. The solution employs the Compact Modular Mid-range PLC AS 300 Series to control the Servo System ASDA-B2 Series and the rotation table. Operators can select different assembly recipes for different types of locks. The Machine Vision System DMV2000 Series localizes components on the conveyor and sends accurate signals for the Servo System ASDA-A2 / ASDA-B2 Series to drive the Articulated Robot DRV90L7 Series. Besides fast and precise movements, the robot features a hollow wrist design that allows retooling for flexible production, which enhances the overall benefits of the solution.

Delta’s Machine Vision Robotic Solution not only meets the requirements of Metal LS with its compact design, but it also offers the advantages of Delta’s worldwide customer service and technical teams to give advice and provide timely troubleshooting. Through clear discussion and on-site evaluation, Delta matched Metal LS’ goals and increased both precision and speed for better productivity and quality with the ideal solution that featured high-precision, high-speed, and flexibility. During the project for Metal LS, Delta’s field application engineering (FAE) team arrived on-site for assembly system construction support with the local partner Mechatronics. With their dedication, the initial results showed significant productivity improvements. 

Delta’s technical teams also support customers in food and beverages, packaging, electronics, and automotive industries. By leveraging its experience from a broad range of customers, Delta helps manufacturers enhance corporate competiveness with smart manufacturing and grasp new business opportunities. 

Metal LS adopted Delta's Machine Vision Robotic Solution, which integrates PLC, HMI, servo system, industrial robot, and machine vision system in one stop to achieve high-speed and high-precision production. The solution also plans for future flexibility in retooling to enhance the benefits of smart manufacturing.