Automated Door Panel Fabrication System

This automated door panel fabrication system, from Dakota Automation, delivers fabricated door panels from the shipping rack to the assembly line, while fabricating on each door surface (strike edge, hinge edge, sill edge, head edge and both faces).
The system features a Fanuc long reach robot that both picks panels from the shipping cart and delivers completed panels to the outfeed queue, in addition to four fabrication stations, a gantry-style overhead pick-and-place system, an inspection station, and (the aforementioned) outfeed queue.
Panels are picked from the shipping cart and placed in the first of the four fabrication stations. Each fabrication station sets up for panel width and height, and each panel is located to the datums before being clamped in position. Transfer of panels between stations is fully automated.
Each panel surface has a dedicated router carriage in one of the fabrication stations. These router carriages feature multiple router motors (with dedicated tooling) that are used to fabricate the required geometry. Fabrications include:
• Hinge pockets (either long edge)
• Strike features (either long edge)
• Head and/or sill details
• Lock/latch features (top surface)
• Face details (top/bottom surface)
The inspection station features an automated profiler system that scans the completed panel for defects.
The system outfeed includes a three panel queue that holds door panels before they are pulled to the assembly line.
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