- Industry > Construction
- Application > Assembly
- Sector > Manufacturing
- #assembly automation
- #industrial robot
- #KUKA
- #modular housing
- #ModularConstruction
- #ModularHome
- #OffsiteConstruction
- #Space Factory
- #window assembly
- #WoodFrameConstruction
Process Overview
BWR developed a fully integrated robotic wooden frame assembly solution for a modular home manufacturer, supporting 42 different framing patterns for window openings.
The system integrates industrial robots, custom-designed robotic grippers, vision systems, and high-payload track motion to automate material handling, positioning, fastening, inspection, and finished frame transfer within a single robotic cell.
Designed for flexible offsite house production, the solution enables consistent automated assembly across varying wall configurations and window opening designs.
The Challenge
For modular home manufacturers, production requires high manufacturing efficiency while accommodating variations in home designs and structural configurations.
Previously, workers manually handled and assembled heavy wooden components to match different frame dimensions and window opening structures. Repetitive material handling and fastening placed significant physical strain on workers and made it difficult to maintain consistent quality.
To address these challenges, the modular home manufacturer required a flexible automation system capable of handling multiple framing patterns while improving productivity, quality, and worker safety.
Components
- Robot
- Industrial Robot (KUKA KR 210 R3100-2)
- Peripherals
Vision System
High-Payload Track Motion
Custom-Designed Robotic Gripper
Workflow
- STEP 1.
- Wooden Component Detection & Positioning ㅡ The vision system identifies variations and deformations in wooden components, such as length and warpage. A custom-designed robotic gripper picks each component individually, feeds it into the cell, and precisely aligns it for assembly.
- STEP 2.
- Robotic Wooden Window Frame Assembly & Fastening ㅡ Once the components are positioned, the industrial robot performs automated fastening according to 42 predefined framing patterns. This enables highly precise and repeatable assembly across wall structures with varying window opening sizes and locations.
- STEP 3.
- Vision Inspection & Frame Transfer ㅡ After fastening, the vision system inspects the assembled frame to verify fastening quality and detect defects. Once inspection is complete, the industrial robot transfers the finished frame to the downstream production stage.
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