In automotive parts manufacturing, the brake pad loading process has long been plagued by two major pain points: low manual sorting efficiency and poor robotic picking accuracy. Faced with stacked parts in bins, traditional automation systems often fail to deliver. But now, the industry finally has an intelligent answer.
Recently, Transfer Technology successfully delivered a 3D vision-guided robotic loading system for brake pads. Powered by advanced machine vision, the solution enables precise recognition and fast picking of 37 brake pad models, bringing a disruptive transformation to automotive manufacturing.
Project Solution
The system adopts an innovative "One-to–Two" configuration: one high-precision 3D camera simultaneously guides two industrial robots to collaboratively complete the loading/unloading of one bin. Once a forklift delivers the materials to the station, the system initiates a 3D scan:
Millisecond-level recognition: The 3D camera quickly scans the entire bin of brake pads, accurately calculating the coordinates and pose of each item.
Smart zone planning: The system automatically divides picking zones. When the remaining quantity reaches a certain threshold, it pre-plans the picking path to reduce processing time.
High-precision localization: Positioning repeatability reaches ±1 mm.
Ultra-fast cycle time: Multiple parts are processed in one scan, with average recognition time under 2 seconds per part.
Technical Highlights
Hardware Configuration：Epic Eye Laser L smart 3D camera paired with an industrial-grade dustproof control unit, is capable of operating reliably in harsh environments from 0–50°C.
Intelligent Algorithms：On-site commissioning completed for 8 major models. Training provided for new model integration, empowering clients to independently expand part recognition categories.
Installation Standards：The camera mount uses 80×80 industrial aluminum profiles and chemical anchor bolts, physically isolating the setup from vibration sources on the production line.
Customer Value
Quality Assurance: >99.5% recognition accuracy prevents missed or incorrect picks that can cause line stoppages.
Flexible Production: Quick switching between 37 different brake pad models, ideal for small-batch, high-mix production.
Improved Yield: Magnetic grippers combined with ±1 mm vision-guided positioning help avoid surface scratches, significantly reducing defect rates.
As Industry 4.0 accelerates, smart vision is becoming a core enabler of intelligent manufacturing. Transfer Technology’s "One-Camera–Two-Robot" solution not only solves the brake pad handling challenge—it also sets a replicable solution for messy material handling in sectors like metalworking and casting.
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