Intelligent Production Line Projects

Intelligent Line Solutions Break Heavy Industry Grinding Bottlenecks
— Neview Automatic’s Line Series Empowers Construction Machinery Group to Achieve Unmanned Production Upgrade

In construction machinery manufacturing, high-volume casting grinding and sorting face dual challenges of efficiency and intelligence. Neview Automatic developed a full-line solution addressing heavy industry needs—from bin picking and tray pre-sorting to line feeding, AI sorting, and smart warehousing. This case study examines a digging machine structural component grinding project for a leading construction machinery group (hereafter "the Customer"), showcasing how Neview Automatic’s line solutions achieve breakthroughs in capacity and precision through unmanned production lines.

I. Customer Challenges: Three Efficiency Barriers in Traditional Lines

As an industry leader producing 100,000+ excavators annually, the Customer’s structural workshop processes 5,000+ daily castings (e.g., iron brackets, counterweights). Their original "manual loading + isolated grinding" model revealed critical pain points:

• Inefficient Logistics: Manual bin picking took 40s/piece, requiring 20 workers. Peak seasons still faced feeding bottlenecks.

• High Changeover Costs: Switching product types required 3-hour manual fixture adjustments, causing ~80,000-piece annual capacity loss.

• Safety Hazards: Open lines generated 2× excess dust, with 5% annual injury rates—failing smart factory standards.

After evaluation, the Customer selected Neview Automatic’s integrated solution ("bin picking + AI sorting + smart warehousing"), leveraging its 210kg payload and ±0.02mm positioning accuracy.

II. Technical Solution: Three Innovations in Fully Unmanned Lines

Neview Automatic’s custom solution centered on KUKA robots, creating an integrated "Smart Identification – Flexible Handling – 3D Warehousing" line:

(1) High-Efficiency Unmanned Bin Picking
Eight DR-750B units with 3D vision achieved 99.8% success rate in disordered grasping of complex brackets. With 2,700mm reach and 210kg payload, per-unit handling stabilized at 20s/piece—100% faster than manual.

(2) Flexible Changeover via AI Sorting
Integrated 3D vision + control system auto-generated handling paths for different parts. Switching from brackets to counterweights reduced changeover from 3 hours to 20 minutes through model-based programming (zero manual teaching), saving ¥3M+ in downtime annually.

(3) Intelligent 3D Logistics Management
A smart warehousing system (2,000kg max load, 300m X-axis / 30m Y-axis travel) enabled automatic buffering and transfer. MES integration boosted logistics efficiency by 40% and space utilization by 3×.

III. Results: Leap from Discrete Production to Smart Lines**

Phase 1 deployed 12 line systems; Phase 2 networked 56 workshop devices:

• Capacity & Efficiency: Daily output per line rose from 500 to 1,200 pieces (+140%). Labor costs dropped 75%, saving ¥8M annually.

• Precision & Quality: Line positioning and compensation achieved ±0.02mm repeat grinding accuracy. Dimensional pass rates rose from 88% to 99.5%.

• Intelligence & Sustainability: Fully unmanned lines reduced dust to 8mg/m³ (meets national standards). Smart warehousing enabled material traceability, raising OEE from 65% to 90%.

The Customer’s Smart Manufacturing Director stated:

"Neview Automatic’s flexible changeover capability liberated us from multi-product constraints. The synergy between AI sorting and smart warehousing elevated our logistics to automotive-grade efficiency."