Case Study

Dual-Robot Spline Rolling Automation: Staffing Reduced by Two-Thirds, 18-Second Cycle, 24/7 Production

Industry: Transportation

A manufacturer of spline shafts for truck and SUV transfer cases was loading and unloading three spline-rolling machines entirely by hand. Three operators were required per shift, throughput was capped by human speed, and the line had no capability for unattended operation. Han-Tek designed, built, and installed a Dual-Robotic Multi-Machine Loading System using two Fanuc R-2000iB robots, nine indexing chain conveyors, and custom dual-gripper end effectors coordinated through an Allen-Bradley ControlLogix PLC. Staffing dropped from three operators to one, cycle time reached one spline every 18 seconds, and the line now runs continuously 24 hours a day, seven days a week.

Their Challenge:

Spline-rolling machines were loaded and unloaded manually, requiring three operators per shift and capping throughput at the pace of human labor.
No capability for unattended production existed: output stopped whenever operators stepped away for breaks or shift changes, making continuous 24/7 operation impossible.
The system needed to handle multiple axle shaft families varying in length, weight, and flange configuration across a single production run, with no manual changeover between part types.
After any line stoppage, a full restart was required from the beginning of the operating cycle, resulting in lost production time and potential rework on every shutdown.

Our Solution:

- Han-Tek designed, built, and installed a Dual-Robotic Multi-Machine Loading System using two Fanuc R-2000iB heavy-payload robots, each fitted with custom dual-gripper end effectors that handle spline shafts simultaneously on both the inbound and outbound sides.
- Nine indexing chain conveyors and five axle table transfers were integrated into the cell to create accumulation buffers at both the infeed and outfeed, keeping parts moving through all three rolling machines even when the operator steps away.
- An Allen-Bradley ControlLogix PLC and two Allen-Bradley PanelView operator stations coordinate all robot and conveyor movements in a single synchronized workflow, enforcing precise timing across all three machines without bottlenecks.
- Five vision identification systems verify part identity and orientation at key handoff points, allowing the system to accommodate the full range of axle shaft configurations without manual changeover between part families.
- Safety fencing was installed throughout the cell, and the robot control software was programmed to automatically drive both robots to a pre-defined safe stopped position whenever the system enters a maintenance or fault state.
- Custom restart logic allows both robots to resume from exactly the position where a shutdown occurred, eliminating the lost cycle time and rework that previously followed every line stoppage.

The Results:

Staffing reduced from three operators to one: Both robots perform all loading and unloading tasks that previously required three operators per shift. One person now monitors and supplies the entire spline-rolling operation.
One spline processed every 18 seconds: The system achieves an 18-second cycle, meeting and exceeding the customer’s original throughput requirement and sustaining that pace continuously around the clock.
Uninterrupted 24/7 production: Conveyor accumulation buffers keep parts moving through all three rolling machines during breaks and shift changes, delivering continuous production that was impossible with the manual setup.
Automatic error recovery on every restart: After any shutdown, both robots resume from exactly where they stopped rather than returning to the beginning of the cycle, eliminating the production loss and rework that previously accompanied every line stoppage.
Maintenance safety built into the system: Robots move automatically to a pre-defined safe stopped position before any maintenance window, and physical safety fencing adds a second layer of protection for personnel working near the cell.
Full part-family flexibility without changeover: Vision identification and custom gripper tooling allow the system to run the complete range of axle shaft configurations in production without manual tooling changes between part families.

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