In this case study…
- Higher testing accuracy with real-time force control,
- Improved reliability despite component tolerances and variability,
- Faster validation through virtual commissioning,
- Reduced scrap and increased process efficiency,
- 60% faster application development through AI-enabled automation.
Today's world faces several challenges. One of them is the transformation of the automotive industry. Electrification, connectivity, shared mobility, and autonomous driving are reshaping transportation. In this new reality, high-precision operations require reliable and repeatable processes capable of handling increasingly tighter tolerances. Minebea AccessSolutions designs intelligent solutions ranging from door handles to keyless systems for vehicle access and security. To ensure high-quality standards and increase production efficiency, Minebea AccessSolutions chose to automate a critical testing phase by implementing Mitsubishi Electric industrial robots equipped with an AI-powered force sensor.
The challenge: managing tolerances and variability without compromising quality
Minebea AccessSolutions needed to develop a highly flexible testing and simulation bench capable of accurately replicating human touch by modulating force values, acceleration, and different geometric trajectories. The goal was to implement a solution capable of dynamically adapting to operating conditions while continuously monitoring the applied load to ensure the highest level of process accuracy.
“We need to develop a test and simulation bench flexible enough to simulate human touch with the ability to measure the level of forced applied acceleration and speed values and different trajectories” Francesco Lamanna, Manufacturing Engineering Manager.
The solution: MELFA robots with force sensor technology
To address these requirements, Minebea AccessSolutions chose to use Mitsubishi Electric MELFA series robots, capable of detecting force during assembly, part processing, and testing operations. This enables the robots to perform tasks that require force adjustment and force detection. As a result, the robot does not simply follow a programmed path but actively responds to contact with the component.
The results: a tailor-made, innovative, high-performance solution
The complete integration of the robot and sensor enabled real-time test traceability and management of the entire system directly through the robot software. Integrated AI models also helped reduce and optimize development and commissioning times. The entire process was digitally replicated and tested within the Gemini Virtual Commissioning software environment.
As a result, Minebea Access Solutions managed to achieve:
- 60% reduction in development time thanks to artificial intelligence functions,
- adaptive force control based on user-defined parameters,
- high execution speed and precision in testing operations with real-time measurement monitoring,
- completing traceability of position and force data at the moment of contact.
Why it matters?
The implementation of the Mitsubishi Electric solution delivered numerous benefits to Minebea AccessSolutions' production process, including:
- greater operational reliability,
- reduced errors caused by tolerances and misalignments,
- improved process quality and repeatability,
- reduced scrap and rework,
- continuous parameter monitoring,
- increased overall line efficiency.
Thanks to the combination of advanced robotics and force control, Minebea AccessSolutions was able to simultaneously improve productivity and quality while maintaining high operational standards even in the most complex applications.
“The technical team has successfully supported the Minebea Mitsumi group, perfectly interpreting our process needs and proposing innovative, concrete solutions that exceed expectations” Vittorio Giaccone, Head of Divisions – Purchasing.
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