TD Conception deploys advanced metal chamfering solution at STIVAL, boosting productivity and workplace safety

TD Conception

TD Conception integrates a metal part chamfering solution at STIVAL

In short

TD Conception , a certified Universal Robots integrator based in Vendée, has developed a sheet metal chamfering solution for STIVAL , a French company specializing in metalworking and the manufacturing of precision metal parts. Integrated in record time at its production site in Saint-André- des-Eaux in the Pays de la Loire region, the cobotic cell operates almost autonomously, without interruption. STIVAL has observed significant productivity gains , while improving the working conditions of its employees.

Boost productivity with fast-tracked cobotic chamfering integration

The project originated from the desire of STIVAL (Société de Tôlerie Industrielle du Val de Loire) to improve the efficiency and productivity of a metal part chamfering station on which a dedicated operator carried out difficult and repetitive movements throughout the day.

Indeed, the position in question was highly arduous, requiring the handling of heavy parts and the use of dangerous tools such as a drill press for machining metal parts. The task, which was particularly repetitive, also generated musculoskeletal disorders (MSDs), including arm and wrist pain at the end of the day. The automation project specifically involved chamfering metal parts, intended for touchscreen tablet protectors, with a view to folding them on another robotic cell. It presented several challenges, particularly in terms of indexing, precision and repeatability. The STIVAL group therefore turned to the certified integrator of Universal Robots in the Pays de la Loire region, TD Conception. The latter was able to bring all its know-how as an integrator of collaborative robotics applications - derived from its long experience in industrial automation - to meet this major challenge.

TD Conception

Industry Metal and Machining

Country France

Number of employees no data

Cobot used UR10e

Main value drivers:

Simplicity and intuitiveness of programming
Almost autonomous operation
Increased productivity
Fast ROI and minimal maintenance

Tasks solved by collaborative robots:

Safe sheet metal drilling
Repetition and precision of the gesture
Reduced downtime and shadow work
Optimization of workstation organization (3x8)

Automation challenges solved:

Improving the quality of machined parts
Reduction of MSDs among operators
Integration in record time into the workshop
Flexibility of the cobotic solution

How they did it

TD Conception powers STIVAL’s growth with smart chamfering automation using UR10e cobot

To meet rising production demands following a major government contract, STIVAL partnered with TD Conception—a certified Universal Robots integrator—to automate its sheet metal chamfering process. Using a UR10e cobot, TD Conception delivered a solution that is fast, secure, and user-friendly. The integration included full support from design to training. Previously, the task required a dedicated operator performing physically demanding manual chamfering all day. Now, the cobotic cell runs nearly autonomously, significantly boosting productivity and improving ergonomics for STIVAL’s workforce.

An automated and optimized workstation

The automated workstation consists of a central mobile chassis on which the UR10e cobot is installed. At the input, the magazine, also mobile and indexable to that of the cobot, is equipped with sensors to determine the bins containing the parts to be picked. The sheet metal stacking/unstacking operation is carried out by the cobot using suction cups - via a vacuum gripper developed and 3D printed by TD Conception.

The next step is to pick up the sheet metal and place it on a re-joining station for referencing. Correctly positioned, the part is then picked up again by the cobot with a gripper - attached to the 3D-printed gripper - to position it on the drilling unit. A final gripper change is carried out via the re-joining station before the part is placed in the output magazine. At the end of the cycle, an operator retrieves the filled bins using a pallet truck to take them to the next workstation, which consists of bending the sheet metal.

An operation in hidden time and at staggered hours

The application was, among other things, designed to fulfill - on time - the large order for 40,000 touchscreen tablet protectors (i.e. 160,000 chamfers to be executed). The primary challenge was therefore to find an economically viable solution allowing for efficiency and productivity gains. Since the cobot can operate without interruption, its installation makes it possible to work in masked time and at staggered hours and thus to evolve towards a "3x8" organization with a night cycle. Automated chamfering therefore brings considerable time savings over the entire operation.

An autonomous cobot to relieve operators of a tedious and repetitive task

Indeed, the cobot handles the operation alone, without the need for human intervention. This is limited to loading the input magazine, which it then indexes onto the cobot's cell before starting the cycle. Directly controlled by the cobot thanks to its integrated communication protocol, the drilling unit is activated thanks to the cobot's programming to make the four necessary holes. The simplicity of both the programming of Universal Robots collaborative robots and the final application is a key factor in the success of this integration. A total of one day of training - with half a day for the operators and another for the technical staff - was enough for the STIVAL teams to take ownership of the cobotic application.

A flexible and mobile solution for easy (re)deployment

TD Conception specifically designed the cell to be easily integrated, transportable, and movable within the factory. Since the cobot plugs into a power outlet and the connections are made via a Harting connector, the solution is fully "Plug & Play." Furthermore, all of the components (hardware and software) were developed and manufactured in-house, making them adaptable and reprogrammable as desired. Since the majority of the components are mounted on wheels, the solution—which is, after all, compact—is therefore very flexible: it can be easily reused at other workstations for various types of processes, such as sheet metal bending, for example.

TD Conception delivers fast, flexible automation at STIVAL—boosting productivity and unlocking operator efficiency

Despite the complexity of STIVAL’s automation needs, TD Conception developed and delivered a custom chamfering solution in just two days. To support rapid decision-making, they provided 3D modeling of the cobotic cell, leading to immediate approval and full integration within three months. Leveraging in-house 3D printing, TD Conception accelerated tool design and avoided delays from external suppliers.

The solution exceeded expectations:

Zero post-installation intervention required
24/5 autonomous operation, ensuring high economic viability
80% time savings for the operator, now focused on quality control
Reduced physical strain and MSD risks, improving workplace ergonomics
Flexible redeployment planned for folding machine operations
Fast ROI and new growth opportunities for STIVAL

TD Conception’s approach not only met STIVAL’s productivity goals but also laid the foundation for scalable automation across its operations.

This application perfectly illustrates the know-how and strengths of TD Conception as a certified integrator of Universal Robots: responsiveness, speed and simplicity of deployment… while leveraging the latest innovations, such as 3D printing, to design flexible solutions for industrial companies.

Dylan Tenailleau, Manager of TD Design

The sheet metal stacking/unstacking operation is first carried out by the cobot using suction cups - via a vacuum gripper developed and 3D printed by TD Conception

The cobot handles the operation alone. Human intervention is limited to loading the input magazine, which it then indexes onto the cobot's cell before starting the cycle.

Correctly positioned, the part is then picked up again by the cobot with a gripper - also 3D printed - in order to position it in the drilling unit

Directly controlled by the cobot thanks to its integrated communication protocol, the drilling unit is automatically activated to make the four necessary holes

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