Automation of tube bending with 3D robot vision

Hutchinson Poland Sp. z o. o., part of the international Hutchinson Group, specializes in manufacturing advanced sealing, insulation, and tubing systems for the automotive industry. Facing challenges related to manual tube loading into bending machines - such as long handling times, repetitive tasks, and the risk of human error - the company decided to fully automate the tube bending process using 3D robot vision.

Cooperation with Procom System S.A. and Pickit 3D

As part of the automation project, Procom System S.A. designed and implemented three robotic workstations for tube loading, equipped with Pickit 3D robot vision. These advanced 3D vision solutions enable precise detection and positioning of tubes, eliminating the need for manual loading. Thanks to their flexibility and quick adaptability to new objects, Pickit 3D robot vision systems can handle a wide range of components - a crucial advantage in today’s dynamic production environments. Moreover, their compact design and ease of integration with various robot brands make them an ideal fit for modern production lines.

One of the biggest challenges during implementation was ensuring reliability under difficult lighting conditions, where glare and shadows could disrupt camera performance. By using an enclosed cell to eliminate reflections and leveraging Pickit 3D’s algorithms, high precision in tube identification and positioning was achieved - even with highly reflective aluminum components.

Despite these challenges, the integration process turned out to be remarkably straightforward and efficient. The robotic stations were quickly deployed, allowing production to resume without significant delays. Additionally, the solution enables rapid changeovers between different tube references, minimizing downtime and increasing overall production responsiveness.

Flexibility, precision, and cost savings

The implementation of Pickit 3D brought measurable benefits to Hutchinson Poland Sp. z o. o., including support for 36 different tube models, which ensured an adequate level of production flexibility. Automation eliminated errors caused by human factors, stabilizing process efficiency. Operators were relieved from repetitive tasks, allowing for more efficient use of human resources. Quick reconfiguration of the system for new tube types enabled more agile production planning and ensured short changeover times between batches. The investment was implemented and managed efficiently, anticipating a favorable return on investment (ROI).

Next steps in automation

The success of the implementation led to Hutchinson Poland Sp. z o. o. ordering two additional identical workstations, proving their satisfaction with the results. In the future, the company plans to use Pickit 3D robot vision systems in other production areas, which may bring further benefits in operational efficiency and cost reduction. With its innovative approach and cooperation with technology leaders, Hutchinson Poland Sp. z o. o. continues to strengthen its position as a key supplier of high-quality components for the automotive industry.