The CR-8503 is a multi-station automation system for processing and assembling small electric meter components. We integrated two independent parts feeders, a rotary indexing table, dual-nozzle precision dispensing, mechanical gripping, multi-axis handling, and an image capture module into one machine, linking part feeding with successive processing operations.
The machine was designed around the need for repeatable part positioning, precise dispensing, and multi-station processing. The indexing mechanism moves workpieces between fixed positions so that separate stations can carry out their tasks within the same production cycle.
Project Background and Automation Requirements
Electric meter components are small, and some require successive feeding, positioning, dispensing, and assembly operations. With manual production or separate workstations, operators repeatedly pick up parts and move them into position at different processing stations.
Repeated clamping takes up cycle time, while manual positioning of small parts is subject to operator-to-operator variation. When operations are spread across several people or standalone machines, handoffs between stations further constrain throughput.
A manual production cell staffed by three operators, each working at 30 seconds per part with 90% effective working time, produces a combined 324 parts per hour. Adding more operators to increase output also requires more floor space and labor expenditure.
For the CR-8503, we used a centralized multi-station layout. Separate feeders handle the different component types; the rotary indexing table connects the processing positions; and the dispensing, gripping, and transfer mechanisms carry out the successive operations.
CR-8503 Machine Design and Production Sequence
The main processing area is built around a horizontal rotary indexing table. Two feeding mechanisms handle different types of components, while the table carries workpieces between primary processing stations. The dispensing unit and other actuators are positioned around the table.
Two independent feeding mechanisms
The machine uses one feeder for small components and another for metal parts.
Small parts travel along a linear guide channel to a fixed pick-up position. A locating feature at the end of the feed track constrains the part before the transfer mechanism hands it off to the next station.
Metal components enter a separate positioning area along a dedicated guide track, where a mechanical gripper and linear motion unit pick them up and transfer them.
Each feeder has its own guide and locating arrangement to suit the component geometry and pick-up requirements. The end-of-track position is aligned with the gripper pick-up point, enabling transfers along a programmed path.
Rotary indexing table and multi-station processing
The horizontal indexing table carries fixtures that secure the workpieces as they move from one processing position to the next. Multiple actuators are arranged around the table.
During a dwell, the stations carry out their respective operations. Once processing is complete, the dispensing heads and other actuators retract clear of the indexing path, and the table advances to its next position.
The multi-station layout can be configured with six to eight stations. In an eight-station arrangement with equal angular spacing, each index is 45°. During each dwell, different stations work simultaneously on parts at different stages of the process.
Because the stations share one indexing mechanism, operators do not have to unload and reload the workpiece into a separate machine after every operation.
Dual-nozzle precision dispensing and part location
The CR-8503 has two dispensing heads mounted above the processing area to apply adhesive at specified locations on the workpiece.
When a workpiece reaches the dispensing station, its fixture holds it in position while the dispensing mechanism follows the programmed path. The mechanism then retracts, allowing the workpiece to advance to the next station.
The position of each adhesive deposit depends on workpiece location, fixture repeatability, and the motion accuracy of the dispensing heads. Precision dispensing assemblies can be configured for positional accuracy of ±0.1–0.3 mm, with mechanical repeatability in the ±0.02–0.1 mm range. Nozzle arrangement, dispensing locations, and motion paths are set according to the part geometry and adhesive application requirements.
Multi-axis handling and image capture
Downstream operations use linear motion modules, vertical actuators, and pneumatic grippers.
The linear modules handle horizontal travel, the vertical actuators approach and retract from the workpiece, and the grippers secure, hold, and release the parts.
During a transfer, the receiving fixture locates the workpiece before the previous gripper releases it. The motion units follow a defined sequence for repeated pick-and-place transfers.
The machine also includes an image capture area with ring lighting and dedicated illumination, integrated with the mechanical positioning and handling system.
Machine Cycle and Throughput
The CR-8503 operates on a synchronized multi-station cycle. Feeders deliver components to defined positions, grippers locate and transfer them, and the indexing table moves workpieces to their processing stations.
While the table is stationary, separate stations work on parts at different processing stages: one may locate a component, another dispenses adhesive, and a downstream station performs assembly or transfer. Once the actuators finish and clear the indexing path, the table advances.
An eight-second production cycle can be allocated as follows:
| Operation | Time allocation | Operating relationship |
|---|---|---|
| Automatic feeding and positioning | 3.0 s | During indexing-table dwell |
| Dual-nozzle dispensing | 5.5 s | Parallel with other stations |
| Assembly operation | 6.5 s | Longest processing station |
| Part transfer | 3.0 s | Parallel with other stations |
| Indexing and auxiliary motions | 1.5 s | After processing actuators retract |
| Overall cycle time | 8.0 s | 6.5 s processing + 1.5 s indexing |
The stations operate in parallel, so the longest processing station plus indexing and auxiliary motions determines the machine cycle. Here, 6.5 seconds for the longest operation and 1.5 seconds for indexing produce an eight-second cycle. At one finished part per cycle, the theoretical output is 450 parts per hour.
At 85% effective uptime, output is approximately 383 parts per hour, or 6,120 parts across two eight-hour shifts.
CR-8503 technical configuration and performance
| Technical item | Configuration / specification |
|---|---|
| Machine model | CR-8503 |
| Industry | Electric meter component manufacturing |
| Machine type | Multi-station automated processing and assembly system |
| Automatic feeding | Two independent component feeding mechanisms |
| Rotary indexing system | 6–8-station configuration |
| Dispensing system | Dual-nozzle dispensing |
| Cycle-time range | 5–10 s/part |
| Cycle time used for throughput analysis | 8 s/part |
| Theoretical output range | 360–720 parts/hour |
| Theoretical output at 8 seconds | 450 parts/hour |
| Dispensing positional accuracy | ±0.1–0.3 mm |
| Mechanical positioning repeatability | ±0.02–0.1 mm |
| Installed power | 2–5 kW |
| Operating air pressure | 0.5–0.7 MPa |
| Vision configuration | Industrial image capture with dedicated lighting |
Production Efficiency, Labor Costs, and Payback
An eight-second cycle gives a theoretical output of 450 parts per hour. At 85% effective uptime, production reaches approximately 382.5 parts per hour.
For manual production, three operators each complete one part every 30 seconds. At 90% effective working time, their combined output is 324 parts per hour.
| Comparison | Manual: 3 operators | Automated: 1 machine + 1 operator |
|---|---|---|
| Cycle time | 30 s/part/operator | 8 s/part |
| Effective working / uptime rate | 90% | 85% |
| Effective hourly output | 324 parts | 382.5 parts |
| Operators per shift | 3 | 1 |
| Daily output across two shifts | 5,184 parts | 6,120 parts |
With two eight-hour shifts, the automated line produces 6,120 parts per day—936 more than the three-operator manual cell, an increase of approximately 18%. Staffing falls from three operators to one per shift, eliminating two operator positions per shift.
Equipment investment and payback
Equipment purchase and installation total RMB 240,000. The fully loaded monthly labor cost is RMB 8,000 per operator, with 22 working days per month.
| Financial metric | One shift | Two shifts |
|---|---|---|
| Operating hours per day | 8 | 16 |
| Operator positions eliminated | 2 | 4 |
| Monthly labor savings | RMB 16,000 | RMB 32,000 |
| Additional monthly operating and maintenance costs | RMB 1,000 | RMB 2,000 |
| Net monthly cost savings | RMB 15,000 | RMB 30,000 |
| Equipment purchase and installation | RMB 240,000 | RMB 240,000 |
| Simple payback period | Approx. 16 months | Approx. 8 months |
With two shifts, labor savings total RMB 32,000 per month. After RMB 2,000 in additional operating and maintenance costs, net monthly savings are RMB 30,000, giving a simple payback period of approximately eight months.
Project Summary and Suitable Production Conditions
The CR-8503 brings two independent feeders, a rotary indexing table, dual-nozzle dispensing, mechanical gripping, and multi-axis handling together in one machine. Fixtures carry the workpieces between stations, while separate actuators perform processing, positioning, and transfer operations during each indexing dwell.
The layout suits small-component production with stable part specifications, consecutive processing steps, and repeated positioning and dispensing requirements.
Station count and cycle time are closely linked. If one operation takes significantly longer than the others, every station must wait for it before the next index. Processes with widely different operation times or frequent product changeovers may instead benefit from standalone workstations or another transfer arrangement.
With one operator assigned to each machine, effective output increases by approximately 18% over three parallel manual operators, while staffing falls by two positions per shift. Two-shift operation provides monthly labor savings of RMB 32,000 and a simple equipment payback period of approximately eight months.
Robotlyne offers a free automation feasibility assessment based on product drawings, manufacturing processes, target throughput, current staffing, and available floor space, followed by a tailored production-line automation proposal.