Case Study | Precision & Efficiency: Transfer Technology’s 3D Vision System Solves Challenges of Intelligent Brake Pad Loading

In automotive component manufacturing, the loading and unloading of brake pads has long been restricted by two core pain points: low efficiency of manual sorting and poor gripping accuracy of traditional robotic automation. Conventional automated equipment struggles to handle disorderly stacked brake pads in material bins, forming a long-standing industry bottleneck. Transfer Technology has delivered an innovative 3D vision solution to break this deadlock.

Recently, Beijing Transfer Technology Co., Ltd. successfully launched a 3D vision robotic gripping project for brake pad production. Adopting advanced machine vision technology, the system realizes precise identification and efficient gripping of 37 types of brake pads, bringing transformative intelligent upgrading for automotive component manufacturers.

Project Solution

The solution adopts an innovative one-camera dual-robot architecture, where a single high-precision 3D camera guides two industrial robots to collaboratively complete full-process loading and unloading for one material bin. After forklifts transport materials to the workstation, the system triggers high-precision 3D scanning immediately:

1.Millisecond-level recognition

The 3D camera rapidly scans disorderly stacked brake pads in the bin and accurately calculates the 3D spatial coordinates and poses of all individual workpieces.

2.Intelligent zoning planning

The system automatically divides optimal gripping zones. When the remaining workpieces in the bin reach the set quantity threshold, it initiates advance scanning and path planning to greatly compress vision processing time and streamline cycle rhythm.

3.High-precision positioning

The vision system achieves a repeated positioning accuracy of ±1 mm, ensuring stable and reliable robotic gripping.

4.Ultra-fast operating cycle

A single scan supports batch processing of multiple workpieces, with the average single-piece recognition time controlled within 2 seconds, delivering high-efficiency continuous operation.

Technical Guarantee

To guarantee long-term stable on-site operation, Transfer Technology has built a complete closed-loop technical system covering hardware, algorithms and deployment standards:

Hardware Configuration

Equipped with the Epic Eye Laser L industrial smart camera and industrial dust-proof industrial controller, the system adapts to harsh workshop environments with temperatures ranging from 0℃ to 50℃, featuring strong environmental adaptability.

Intelligent Algorithm Empowerment

The project completes debugging and adaptation for 8 mainstream brake pad models on site. Professional training for new model expansion is provided, enabling customers to independently add and identify new product types for flexible production iteration.

Standardized Deployment

The camera bracket adopts 80×80 industrial aluminum profile and chemical bolt fixing structure, achieving physical isolation from production line vibration sources to ensure long-term imaging stability and positioning accuracy.

Customer Value

Stable Production Quality

The system maintains a recognition accuracy rate above 99.5%, effectively eliminating production line shutdowns caused by missed gripping and mis-gripping, and securing continuous and stable production operation.

Enhanced Production Flexibility

It supports rapid switching among 37 brake pad specifications, perfectly matching the modern production demands of small-batch and multi-variety manufacturing modes.

Higher Product Yield

Combined with magnetic suction fixtures and ±1 mm high-precision visual positioning, the system avoids surface scratches and structural damage to brake pads during gripping, effectively reducing product scrap rate.

With the accelerated advancement of Industry 4.0, intelligent vision technology has become core infrastructure for smart manufacturing. The innovative one-camera dual-robot 3D vision solution not only solves the industry-specific gripping difficulties of disorderly brake pad workpieces, but also provides a replicable and scalable technical template for scattered and irregular material handling in hardware, casting and other manufacturing fields.