Adaptec Reaches New Heights in Forging Automation
Industry Overview
Forging is a manufacturing process that shapes metal using compressive forces, typically applied through hammers, presses, or dies. Advanced automation solutions are increasingly being implemented to help forgers address labor shortages, enhance operational efficiency, and improve workplace safety. Traditionally labor-intensive and physically demanding, forging is being reshaped by robotics, advanced vision, and control systems.
Key areas of automation include:
- Material handling of bulk materials
- Forging press operations
- Quality control
- Die lubrication
- Data integration
Robotic Bin Picking Solution
Adaptec’s engineering team paired Keyence’s advanced vision system with FANUC’s precision robots to create a new standard for bin picking systems. Integrating the two technologies allows the system to seamlessly identify and pick randomly oriented parts from bins, resulting in increased efficiency, flexibility, and reliability. Read our original bin picking case study here: Metal Forging Company Implements Keyence Vision Bin Picking System
At Forging Industry Association’s (FIA) 2025 Forge Fair trade show this May, Adaptec exhibited its Keyence bin picking system with a new 3D scanning technology. Partnering with Manufacturing Automation Systems (MAS), Adaptec integrated MAS’ QC Plus robotic scanning system to improve quality control in the bin picking process.
Special Features & Key Partnerships
FANUC robots, specifically their FoundryPro series, are engineered to endure the harsh environmental conditions commonly found in forging operations. With six axes of motion, FANUC robot arms can replicate and surpass the complex movements of a human operator.
The Magswitch magnetic gripper is mounted to a custom heavy-duty steel tool frame to create an end-of-arm tool optimized for random bin picking and high product mix applications with minimal changeover.
Keyence’s vision system, powered by advanced software, enables the robot to identify and pick randomly oriented parts from a bulk container. In addition to guiding the robot’s movements, the system detects and avoids potential interferences between the end-of-arm tool, adjacent parts, and the container’s side walls.
The MAS QC Plus Hexagon AS1 Kit features a scanner head and laser tracking system that allows the robot to perform high-precision 3D scanning of parts, generating a point cloud with accuracy better than 50 microns. This data can be leveraged for dimensional analysis, defect detection, and adaptive robot path planning, ensuring real-time feedback and process optimization. The QC Plus software by MAS integrates all this 3D measurement capability to the robot controller and supports intelligent manufacturing by enabling closed-loop process control.
Key Results
- Eliminate safety and ergonomic challenges for operators by utilizing robotic bin picking to unload bulk parts
- Increase inspection accuracy and data collection via automated metrology
- Remove human error and subjectivity surrounding defect detection
- Enable adaptive process control by doing work only in areas that the product does not conform to specifications
- Eliminate COPQ by ensuring product conforms to specifications before advancing to next step in the manufacturing process
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