Material Handling Automation for Metal Sheets with Estun Robot

Client Profile

The client operates in a manufacturing environment handling flat, surface-sensitive parts such as metal sheets and fabricated panels. With increasing production demands, manual handling was no longer able to ensure consistency and efficiency.

The Challenge

Handling large, flat metal sheets in continuous production introduced several specific challenges:

• Sheet Flexibility During Handling：Thin metal sheets tend to bend or sag during lifting, making stable pickup and placement difficult
• Uneven Load Distribution in Vacuum Gripping：Single-point or poorly distributed suction can cause partial lifting or slipping, especially on larger panels
• Surface Protection Requirements：Even minor contact or misalignment during transfer can lead to scratches or dents on visible surfaces
• Position Drift Between Stations：Small deviations during handling accumulate, affecting alignment in downstream processes such as welding or assembly
• Inconsistent Handling Rhythm Between Processes：Manual or semi-automated handling made it difficult to maintain consistent transfer timing between stations

Our Solution

We implemented a material handling system built around an Estun 6-axis industrial robot, combined with a vacuum-based end-effector and a servo-driven positioning base.

• Robotic Handling Execution：The 6-axis robot enables flexible and repeatable pick-and-place operations across different positions and orientations
• Array-Type Vacuum Gripper：A multi-cup suction system distributes vacuum force evenly across the sheet surface, ensuring stable lifting of flat parts
• Servo Positioning Base：A short-stroke linear base allows precise positioning adjustment, improving alignment accuracy during transfer
• Non-Contact Handling Approach：Vacuum gripping minimizes surface damage, making it suitable for surface-sensitive metal sheets

  

Implementation

• System Installation & Commissioning
  The system was installed and tested on-site to ensure stable operation under real production conditions
• Process Validation
  Handling performance was verified through continuous operation and adjustment to match production requirements
• Operator Integration
  The system was configured to work alongside existing workflows, ensuring smooth adoption

The Outcomes

Based on one week of continuous operation testing, along with on-site commissioning and feedback from engineers and operators, the following improvements were achieved under stable production conditions:

• Positioning consistency improved by 28.8%
• Handling-related surface damage reduced by ~25%
• Operator intervention reduced by 40%
• Overall process stability significantly improved

  

About Aixsen

At Aixsen, we deliver end-to-end industrial automation systems designed for demanding manufacturing environments.

We deliver precision laser cutting, robotic arc welding, and intelligent material handling solutions—designed as standalone systems or integrated lines, fully engineered around your specific process, quality requirements, and output targets.