A fuel cell manufacturer required an automated sorting system to replace a slow, manual testing process for non-rigid porous foam components. The existing machine tested parts by measuring airflow impedance to sort components based on quality specifications, but the cycle time severely constrained production throughput. The client needed a turnkey automated workcell capable of testing, rotating, sorting, and binning delicate foam parts at a cycle time under 5 seconds—a dramatic improvement that would require complete redesign of the testing equipment, material handling systems, and process flow while maintaining product integrity throughout high-speed operations.
The Details
Industry
Robotics & Industrial Automation
CAPABILITIES APPLIED
The project presented multiple interconnected technical challenges requiring innovative automation solutions and precision engineering:
Accelerated Cycle Time Requirements: The original testing machine operated at an unacceptably slow cycle time that limited production capacity. The complete process—including part singulation, testing, rotation, sorting, and binning—needed optimization to achieve sub-5-second cycles, representing a significant throughput improvement while maintaining testing accuracy and part quality.
Delicate Material Handling Without Damage: Non-rigid porous foam components are highly susceptible to deformation, tearing, and compression damage during handling. Traditional pick-and-place automation technologies proved inadequate, as mechanical grippers and standard vacuum systems either crushed the foam structure or failed to maintain secure grip during transport and rotation operations.
Precise Singulation from Stacked Configuration: Separating individual foam parts from stacked configurations without damaging adjacent parts or the part being picked required extremely precise control of vacuum flow rates and contact pressure. The porous nature of the material complicated vacuum grip dynamics, as airflow could pass through the foam rather than creating reliable suction hold.
Press and Tester Inadequacy for High-Speed Operation: The existing system utilized a repurposed arbor press that proved structurally insufficient for repeated high-speed testing cycles. The press mechanism was prone to cracking under operational demands, while the tester’s stroke length created unnecessary cycle time delays that prevented achievement of the 5-second target.
Constrained Equipment Integration: Dimensional requirements of existing production equipment created severe spatial constraints for the automated system. The workcell needed to integrate robotics, testing stations, sorting mechanisms, and binning systems within a tightly defined footprint while maintaining ergonomic access for operators.
Continuous Operation with Operator Access: The system required design features enabling operators to safely load raw materials and unload sorted parts without interrupting the automated testing cycle. This demanded careful safety interlocking, ergonomic work zones, and intelligent cycle coordination to prevent production stoppages during material replenishment.
Re:Build delivered a fully automated foam sorting workcell achieving sub-5-second cycle times while safely handling delicate porous materials.
The solution used precision-calibrated vacuum cup technology to singulate and transport foam parts without damage. A custom-engineered robust weldment replaced the failing arbor press, while an optimized tester design with reduced stroke length significantly decreased cycle time.
A compact robotic system operated within severe spatial constraints, integrating material handling, testing, rotation, sorting, and binning. Operator-accessible loading zones with safety interlocks enabled continuous operation without cycle interruption.
Following Factory Acceptance Testing (FAT) at Re:Build’s facility and Site Acceptance Testing (SAT) at the client’s plant, the system entered production. The automated workcell transformed production capability, enabling high-volume fuel cell component manufacturing with consistent quality, reduced labor, and dramatically improved throughput.
