Fonderia di Torbole- robot Kawasaki for handling brake discs

The Tiesse Robot project for a historic italian foundry

The evolution of industrial automation is not solely measured by the adoption of increasingly advanced technologies, but also by the ability to orchestrate complex solutions capable of managing complete production cycles in total autonomy. It is within this context that a recent project by Tiesse Robot has been implemented for a renowned Italian foundry specialising in the production of components for the automotive sector.
The objective: to automate the brake disc handling process - from the gripping of raw parts to preparation for painting - by integrating three interconnected robotic islands designed to operate in perfect synergy.

One system, three islands, one seamless process

At the heart of the project lies a system divided into three operational islands, each dedicated to a specific phase of the production cycle: loading of raw parts from bulk bins, post-turning intermediate operations, and final inspection and outfeed. Every stage has been engineered to ensure continuous, synchronised and smooth material flow, along with repeatability and precision, all while reducing human intervention to a minimum.

Type of parts handled

Metallic brake discs made of cast iron or steel
Ø from 230 to 400 mm
Height: 32–55 mm
Maximum weight: 15 kg
Cycle time: 45 seconds

Island 1 - loading raw parts from bulk bins

The first island is dedicated to retrieving raw brake discs from bulk bins. This is where 3D vision comes into play, using the Photoneo PhoXi Scanner XL with structured light technology, allowing the Kawasaki Robotics RS080N robot (6-axis, 80 kg payload) to identify the orientation of each disc, select correctly positioned parts, and flip those that are upside down before transferring them to the turning line.
Gripping is performed by a magnetic gripper, ensuring reliable handling even when parts are partially visible or irregularly placed. Each phase - gripping, flipping, and depositing onto the powered roller conveyor - is fully automated to guarantee smooth workflow continuity.

Island 2 - post-turning operations: drilling, balancing

Once the turning is complete, the discs move on to the second island, where intermediate operations are performed. The Kawasaki Robotics ZX165U robot (6-axis, 165 kg payload), equipped with a dual pneumatic three-jaw gripper, conducts an initial scan using TS-Vision, a proprietary vision system developed by Tiesse Robot, to determine the correct phasing of each disc.
Following the analysis, the robot automatically handles the loading and unloading of two drilling units and subsequently, the balancing station. Once this stage is complete, parts are sorted according to processing results: compliant discs continue on to the washing machine, while rejects are directed automatically to a gravity conveyor.

Island 3 - final inspection and line outfeed

In the final stage, the washed discs undergo a series of inspections and are given a unique identification marking. Here too, a Kawasaki Robotics ZX165U robot operates with a dual pneumatic three-jaw gripper, managing the handling of parts across various units: dimensional inspection, Keyence laser marking, and finally outfeed either onto the customer’s roller conveyor or to a transfer belt leading to the painting system.

Technologies supporting workflow continuity

This installation is a prime example of integrated automation, where physical part movement is only one dimension of a broader operational system. A number of technologies support the process, including:

• Vision systems: 3D structured light for bin picking; 2D vision for phase alignment
• High-load capacity robots: Two ZX165U robots (165 kg payload) and one RS080N robot (80 kg payload)
• User-friendly interface: Intuitive touchscreen interface for managing formats and parameters
• The entire system is future-ready, designed to allow for upgrades such as pallet magazine integration, remote monitoring, and connection to data collection and traceability systems.