Automating Quality with Precision: Robot Integration

Aggressive Tooling is proud to partner with our customers on a cutting-edge automation project that showcases both our engineering creativity and our controls expertise.

Our team recently supported the integration of a Yaskawa MH80 robot into our customers’ existing mold press system, which includes a Fanuc S2000iB-330. The robot was strategically mounted overhead, allowing it to work seamlessly with both new and existing part designs.

Here’s how it works: The robot picks up two freshly molded footrest components and transfers them into a custom-designed “nest.” From there, an advanced AI vision system inspects each part for defects. Based on the inspection, the robot sorts the parts—flawed pieces are discarded down a chute, while good parts are neatly stacked into boxes, ready for the next stage in production.

To enhance quality control, our controls engineers added a clever twist: the robot is programmed to randomly place select parts into a designated pull-out drawer. This allows operators to perform ongoing quality checks and ensure long-term consistency in the molding process.

Additional highlights include:

• Custom PLC and HMI programming for seamless communication between systems

• Sensor-equipped framing that supports a 4-station box loading area, alerting operators when boxes are full or need replacing

• Smart stacking of up to 216 parts per box, improving efficiency and reducing manual handling

• Precision pneumatic integration, with metric fittings and cylinders to match customer equipment standards

This project is a great example of how Aggressive Tooling helps our customers modernize their processes, improve quality, and reduce manual labor—all while keeping flexibility and operator ease-of-use top of mind.