Automation Production Line for JAKA Robot Sensor Products

Shenzhen Aihua Technology Co., Ltd. (hereinafter referred to as “Aihua”) has integrated 10 JAKA C5 collaborative robots into its sensor products’ automation production line. These robots perform precise and efficient tasks such as material handling, inspection, and unloading. They also facilitate meticulous electric current sensor testing and laser adjustment processes, ensuring high-quality mass production of products. The phrase, “Robots are the new workers; automated production lines are the new products,” could become a key to growth in the manufacturing sector.

Advantages

Robots enable 24/7 operations, addressing the complex turnover challenges of manual production for precision sensor components. They collaborate in critical processes like testing and laser adjustment, which helps prevent misjudgments and omissions during inspections, reducing error rates and boosting product quality rates to over 98%. This minimizes quality losses and ensures timely product delivery.

Production Line Details

• Open-loop Hall Current Sensor HCK10-100..600S/J
  • Original line: 1 station with 1 worker
  • After transformation: 1 worker manages 2 robots, ROI period < 8 months
• Product Laser Adjustment
  • Original line: 2 stations with 2 workers
  • After transformation: 2 robots complete tasks at 2 stations, significantly improving efficiency
• Open-loop Hall Current Sensor K17E-XXXP
  • Original line: 1 station with 2 workers
  • After transformation: 1 worker manages robots operating across 4 stations, ROI period < 8 months

Aim for Automation

Since 2013, as the technology level in China’s manufacturing sector has improved, Aihua seized the opportunity presented by the domestic substitution trend. They identified a gap in sensor manufacturing and the need for cost reduction and efficiency improvement within the industry, leading to the production of high-quality, affordable current sensors. To date, Aihua has gained numerous major clients in various sectors, including inverters, photovoltaics, wind power, and new energy vehicles, significantly enhancing their market influence with a tenfold increase in monthly orders from tens of thousands to hundreds of thousands of units.

Intelligent Manufacturing Solutions

In 2022, Aihua invested in JAKA robots to further enhance product competitiveness by lowering costs and improving quality and efficiency through automation and intelligent upgrades in their production lines. Aihua boasts a strong product R&D and operational management team, having designed their factory automation line, detailing the operational logic and performance indicators. This includes simulating manual operations, integrating hardware and software solutions, and utilizing information platforms for real-time updates and monitoring of production processes. Robots equipped with end-effectors and sensing products compensate for the dexterity of human hands, ensuring accurate detection, differentiation, and placement of good and defective products.

Flexibility and Efficiency

The combination of “fixed” and “non-fixed” elements on the industrial assembly line addresses both product characteristics and operational environments. “Fixed” refers to rigorous quality control of process logic and performance standards, while “non-fixed” emphasizes product flexibility, allowing for diverse developments and the ability to meet rapid production changes. JAKA robots perfectly fulfill Aihua’s needs with flexible deployment and quick product changeovers in just 20 minutes.

Compact and Efficient Design

The compact structure of the JAKA robots allows for complex motion paths in small spaces. Their efficient design enhances the unit output value of the production line, simulating realistic manual operation scenarios for dual-station material handling, inspection, and unloading tasks. Compared to manual operations, the JAKA C5 robot ensures a clear workflow, continuous operation, and stable running, supporting timely and precise production.

User-Friendly Automation

With a simple graphical programming system and a user-friendly interaction model, the JAKA robots lower the threshold for automation equipment, reducing the learning curve for machine operation and enabling workers to quickly engage in production activities.

Future Plans

“In the future, Aihua plans to procure more robots for collaborative inspection across other product lines and actively expand applications in labeling, packaging, and other scenarios, facilitating traceable product production,” stated Wu Jianan, CEO of Shenzhen Aihua Technology Co., Ltd. “The infinite ‘past’ finds its home in the ‘now’, while the infinite ‘future’ derives from the ‘now’.” Ten years ago, Aihua ventured into the sensor manufacturing sector and has thrived since. Looking ahead, JAKA robots will empower Aihua’s factory to navigate the challenges in the sensor field characterized by high output and low product value, while promoting a significant leap in production capabilities across downstream industries such as industrial control, automotive, and photovoltaics.