Rotavator Blade Handling & Automated Forming System

Rotavator blade manufacturing involved multiple manual handling and forming operations. Approximately 12–14 operators handled and transferred blades through shaping and heat treatment.

• High manpower requirement and labour costs
• Limited production capacity due to manual handling
• Multiple stations occupying shop-floor space
• Separate furnace for additional blade heating
• Increased furnace gas consumption
• Tooling and maintenance issues at lower forming temperatures
• Variation in part temperature during forming
• Additional handling between forming and heat treatment
• Inconsistent production cycle times

An optimised production configuration with 3 industrial robots and 3 major stations.

• Automated handling between processes
• Controlled positioning and forming
• Accurate temperature management before final forming
• Direct quenching after final forming

• Reduced Manpower: Less manual intervention than the previous 12–14-operator process.
• Higher Production: Approximately 11–12 sec/set or 7–8 sec/set, depending on configuration.
• Compact Layout: Fewer stations and reduced material movement.
• Additional Furnace Eliminated: Direct transfer from final forming to quenching.
• Reduced Gas Consumption: Removal of the additional heating stage reduced associated operating costs.
• Temperature Control: Consistent temperature conditions at final forming.
• Improved Tool Life: Controlled forming temperatures helped reduce tooling and maintenance issues.
• Consistent Production: Repeatable positioning, sequencing and cycle times.