How to Choose Between 6-Axis Robots and Forging Manipulators in Gear Forging Automation

In gear forging automation, the question is no longer whether to automate, but how to automate correctly.

One of the most common questions we receive from gear manufacturers is:
Should we choose a 6-axis robot or a dedicated forging manipulator?

The answer depends on the forging process, gear type, and production rhythm.

6-axis robots offer high flexibility and are ideal for multi-product gear forging lines, especially for small to medium-sized gears. They perform well in handling, transfer, and downstream operations where positioning accuracy and adaptability are required.

Forging manipulators, on the other hand, are designed specifically for hot forging environments. They provide excellent rigidity, high load capacity, and stable cycle times, making them suitable for heavy gear blanks, high-temperature handling, and high-volume continuous production.

---Case 1: Automotive Gear Blank Production Line

In an automotive gear blank project, the customer focused on high output and long-term stability. Gear blanks were forged at high temperatures and transferred directly from the furnace to the press.
A forging manipulator was selected to ensure stable handling, precise timing with the forging press, and reliable 24/7 operation. The result was a significant reduction in manual intervention and improved line consistency.

---Case 2: Planetary Gear Forging Line

For a planetary gear project involving multiple gear sizes and frequent changeovers, a 6-axis robot was implemented.
The robot provided flexible motion paths and accurate positioning, allowing quick adaptation to different products while maintaining stable production. This solution helped the customer balance flexibility with automation efficiency.

In many modern gear forging projects, a hybrid solution is often the most effective:
forging manipulators handle the hot and heavy operations, while 6-axis robots manage flexible downstream handling.

In gear forging automation, the best solution is always process-driven, not equipment-driven.