Challenge
A major automotive manufacturer wanted to automate the assembly of turbocharger sandcast components to reduce cycle time, improve consistency and remove repetitive manual handling. The target was ambitious: one fully assembled unit every 13 seconds.
The challenge was that sandcast components vary in geometry, texture and mass. Each variation needed to be picked, rotated, aligned and nested with extremely high precision. The system also had to fit around an existing index table and operate with two fast, six-axis robots working in close proximity, where even a small positioning error could cause a collision or jam.
In short: create a high-speed automated system that could handle inconsistent parts with absolute repeatability, without compromising safety or uptime.
How Amtek Tackled It
The first step was to understand the full workflow. We analysed every movement across the workstation positions, mapping how each component travelled and where tolerances were tightest. Rather than treating each robot task separately, we designed the process as a single coordinated system.
Sandcast parts are rarely identical, so we prototyped and tested a wide range of gripping and handling concepts. Each end-of-arm tool was developed to accommodate variations in shape and finish while still placing parts accurately. We refined actuation methods, force levels and release strategies until we achieved the reliability needed for a rapid takt time.
Two robots and a rotating index table leave little room for error. We introduced a robust mechanical disengagement mechanism designed to protect equipment if an unexpected contact occurred. This gave the system a safety envelope that allowed high speed operation without unnecessary downtime or risk.
A major focus was keeping the system stable over long production runs. We carried out extensive isolation testing and cycle simulations, refining robot paths and timings to ensure smooth, repeatable assembly at full speed.
The goal was simple: a system the operators could trust, one that kept running reliably without constant adjustment.
The Solution and Its Impact
Amtek delivered a single-operator automated sandcasting assembly system that met the customer’s 13-second cycle time while handling multiple part variations with consistent, reliable precision.
The customer gained:
- Fast, dependable production
The system maintained the required takt time without jams or alignment issues, giving stable throughput. - Reliable handling of variable components
The end-of-arm tooling and motion strategy were designed to tolerate natural sandcast variation while still placing each part accurately. - Built-in collision protection
The mechanical disengagement mechanism protected tooling and robots, reducing the risk of costly damage and downtime. - Reduced operator workload
Automation removed repetitive manual handling, allowing operators to supervise rather than intervene. - Improved product quality and consistency
Automated alignment ensured every unit was assembled accurately, reducing scrap and rework.
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