Customer Background & Requirements

A global motorcycle manufacturer was facing significant challenges in the raw material handling stage of its aluminum casting process. On this production line, long aluminum ingots were stacked up to 21 layers high, with each ingot weighing approximately 7 kg.

Due to the physically demanding, repetitive nature of the task and the high positioning accuracy required during pick-and-place operations, the customer aimed to completely replace manual labor with an automated solution combining a robotic arm and an AI vision system. The key objectives were:

• Reducing labor costs
• Improving positioning accuracy
• Enhancing workplace safety in the casting line

Challenges

High workload and injury risk

Repeated bending and lifting of 7 kg aluminum ingots over long periods posed a serious risk of occupational injuries, particularly to workers’ backs and spines. This issue became even more critical in the context of the ongoing shortage of skilled labor.

Limited field of view (FOV)

Due to the long shape of the aluminum ingots, conventional cameras were unable to capture the entire workpiece in a single frame at close range. This made accurate detection of the optimal gripping position extremely difficult.

Complex stacking pattern

The ingots were arranged in an alternating pattern across 21 layers, with highly reflective metal surfaces. As a result, traditional vision systems struggled to accurately identify depth, contours, and the exact position of each individual ingot.

Cost constraints

The customer did not want to invest in expensive 3D cameras, instead prioritizing a cost-effective solution that could still deliver reliable performance in an industrial environment.

Implemented Solution

Techman AI Cobot – S Series

Techman deployed a high-performance AI vision solution that leverages advanced software algorithms to overcome hardware limitations:

AI-based object segmentation (2D instance segmentation instead of 3D)

Rather than relying on costly 3D cameras, the system uses AI-powered object segmentation on 2D images. With a specially trained deep learning model, the solution is able to:

• Accurately recognize each individual aluminum ingot
• Clearly distinguish between stacked layers
• Identify contours even on highly reflective surfaces

This approach significantly reduces hardware costs while still meeting the technical requirements of the application.

Proprietary positioning algorithm for long workpieces

To address the field-of-view limitation, Techman developed a dedicated positioning algorithm:

• The system independently detects both ends of the aluminum ingot
• Based on these two points, the software automatically calculates the center point and center of gravity

This enables the robot or cobot to grip the ingot at the optimal position, ensuring stability and safety during lifting operations.

Achieved

Increased productivity

With just a single robotic arm, the system can service a work area equivalent to four pallets, achieving a throughput of approximately 100 aluminum ingots per hour.

Optimized investment costs

By replacing expensive hardware with intelligent AI algorithms, the customer significantly reduced equipment costs and shortened the return-on-investment period.

Safer working environment

The entire heavy lifting and handling process was fully automated, eliminating the risk of injuries caused by prolonged bending and manual handling. This contributes to a safer and more sustainable production environment for workers.

This case study clearly demonstrates that advanced AI vision software can effectively overcome the physical limitations of hardware.

By combining precise positioning algorithms with a cost-efficient 2D vision approach, Techman’s solution not only successfully addressed a complex aluminum ingot handling challenge, but also delivered dual benefits for the customer:

• Higher production efficiency
• Improved occupational safety on the casting line

A compelling example of the real-world value of AI Vision combined with collaborative robots in modern industrial manufacturing.

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Temas is the official distributor of Techman collaborative robots in Vietnam and brings extensive experience in deploying robot solutions integrated with AI vision for pick-and-place, sorting, feeding, and material handling applications across casting, mechanical engineering, and industrial manufacturing sectors. Contact Temas for in-depth consultation and a tailored solution assessment for your factory.