Heavy loads safely under control
Zimmer Group gripping system for human-robot collaboration at Scania
High quality requirements, increasing product diversity, and the ongoing shortage of skilled workers call for new, flexible automation concepts—especially in foundries and mechanical reworking of large components. Purely manual handling reaches its limits, especially with heavy engine and cylinder blocks, while complete automation is often not economically or technologically feasible due to complex testing processes.
Against this backdrop, Zimmer Group implemented a powerful gripping system for integrator MRK-Systeme GmbH for handling truck engine blocks and cylinder heads for end customer Scania. The major challenge here was to connect workpieces weighing up to 400 kg that are designed for use in human-robot collaboration (HRC).
Challenge: 400 kilograms of precision
In the quality inspection of cast parts, a large part of the working time is traditionally spent on moving the components into a suitable test position using manipulators. The actual core competence of the employees – the reliable detection of casting defects – takes a back seat in terms of time.
The aim of the project was to optimize the non-value-adding handling steps while retaining human expertise in the inspection process. That is why Scania uses four heavy-duty robots. They pick up the engine and cylinder blocks, which weigh up to 400 kg, position them precisely, and make them available to employees for inspection in an ergonomically optimal position. At the heart of this solution is the specially developed heavy-duty gripping system from the Zimmer Group. This has already enabled more than 300,000 workpieces to be inspected in a cycle time of only 210 seconds using semi-automated processes.
Customized gripping system for maximum process reliability
For this demanding application, Zimmer Group has developed an application-specific end-of-arm tool (EOAT) that meets the highest requirements for load capacity, process stability, and user-friendliness. After the casting process, the engine blocks are transported for post-processing and quality inspection. The gripping system automatically removes the components from the conveyor belt, secures them in place, and positions them precisely in the operator's workspace. The necessary safety concept was closely coordinated with MRK-Systeme GmbH, the expert for MRK applications.
The key requirements for the EOAT were therefore:
- High load capacity combined with a compact design
- An MRK-compatible safety concept
- Robust components suitable for the harsh foundry environment
- Process-reliable repeatability even over high quantities
Intuitive operability in the MRK environment
A central element of the application is the direct collaboration between humans and robots. Employees can intuitively adjust the orientation of the component in the gripper using a joystick if a different test position is required.
Zimmer Group's gripping system is designed to enable controlled and sensitive rotation and swivel movements. The workpiece is guided stably at all times, ensuring that the interaction between humans and machines remains safe and predictable. With this hybrid automation, handling is completely taken over by the system, while the quality decision remains with the experienced employee.
The heavy-duty EOAT combines the robustness of classic industrial automation with the flexibility and process proximity of an HRC application. Only a specially designed gripping concept enables standard industrial robots with high payloads to use heavy cast components safely and economically in the immediate operator environment.
Sustainable increase in productivity
After more than two years of operational experience, the system has proven itself at Scania.
The solution exemplifies a key trend in the industry: intelligent gripping technology is the key to hybrid automation concepts. Where full automation reaches its limits, a sophisticated gripping system creates the link between human expertise and robust industrial automation – precise, safe, and future-proof.
Further information on our gripping systems can be found here:
