APPLICATIONS OF ROBOTS IN THE

AUTOMOBILE INDUSTRY

So far, robots have been mainly used in the automotive industries, including their supply chains, accounting for more than 60% of total robot sales. Typically prime targets for robot automation in car manufacturing are welding, assembly of body, motor and gear-box, and painting and coating. Automotive industries, as the key application driver in terms of cost, technology and services robotics industry, are subject to fierce global competition.

Origin of robot supplier in the automotive industry

Advantages of Using ROBOTS

• Cost Effectiveness : A robot can work twenty-four hours a day without a break, and continuously perform the same mundane tasks over and over again virtually non-stop.

• Job Efficiency : Barring any computer errors, robots will almost always get the job done quicker and more efficiently than a human possibly could.

• Safety : Robots are able to withstand exposure to extreme heat, chemicals in the air, and general physical contact with parts and structures.

• Accuracy : Robots are able to be programmed to perform precise intricate duties at much faster speeds than any human could be expected to.

• Physical Capacity : Robots are not limited like humans when it comes to performing many assembly jobs like painting, finishing, welding, riveting, and installation. Robots also don't have restrictions with moving heavy objects or issues of fatigue.

The application of Robotics is mainly in the final step – execution of design process and assembly operations

The assembly processes are done at the different level of automation giving a possibility of comparing and choosing the best automation strategy for the particular plant location. The final assembly consists of the three main processes called Assembly Parts. Each Assembly Part in turn can be divided into Assembly Operations or Stations.•Assembly Part 1 consists of five Assembly Stations and includes the following: roll forming of a tailgate and doors and a fitting of the cockpit.•Assembly Part 2 also consists of five Assembly Stations and includes mainly a fitting of the power train and glasses.•Assembly Part 3 includes seven Assembly Stations, which are typically fitting of trim panels, a cross member, a bumper, a complete front end, wheels and a battery.

AUTO ASSEMBLY PROCESS

Stamping• Stamping

out and cutting parts from sheet metal

Gripping• Robotic

arm, controlled by computer, used to move objects and place things

Welding• Spot Welding• Arc Welding-------------------------------------

-------– Parts can be welded

either through the movement of the robot or by keeping the robot relatively stationary and moving the part past the robot.

– For unmatched repeatability, uniformity quality, and speed.

Body in White Operation

• The shell of the vehicle passes through a brightly lit white room where it is fully wiped down by visual inspectors using cloths soaked in hi-light oil.

• Under the lights, this oil allows inspectors to see any defects in the sheet metal body panels.

• Dings, dents, and any other defects are repaired right on the line by skilled body repairmen.

Spray Painting• E- coat

– an electrostatically charged bath of undercoat paint (called the E-coat) that covers every nook and cranny of the body shell, both inside and out, with primer. This coat acts as a substrate surface to which the top coat of colored paint adheres.

• After the E-coat bath, the shell is again dried in a booth as it proceeds on to the final paint operation.

• Once the shell has been fully covered with a base coat of color paint and a clear top coat, the conveyor transfers the bodies through baking ovens where the paint is cured at temperatures exceeding 135 degrees Celsius.

Spray Painting Operation

Interior assembly

Assembly of all of the instrumentation and wiring systems, dash panels, interior lights, seats, door and trim panels, headliners, radios, speakers, all glass except the automobile windshield, steering column and wheel, body weather strips, vinyl tops, brake and gas pedals, carpeting, and front and rear bumper fascias.

Windshields used to be installed by hand

Today, windshields are installed by robots

Body and chassis mate

The chassis assembly conveyor and the body shell conveyor meet at this stage of production. As the chassis passes the body conveyor the shell is robotically lifted from its conveyor fixtures and placed onto the car frame. Assembly robots, some at ground level and some in work pits beneath the conveyor, bolt the car body to the frame.

Body and chassis mate

Final Assembly• Tyres• Batteries• Gasoline• Anti-freeze

Robot fuelling

Trim line

• Final Inspection audit• Checkpoint off the line• Troubleshooting• Price label

Kuka KR 500 Robot• Axes: 6• Payload: 500 kg• H-Reach: 2836 mm• Repeatability: ±0.15 mm• Robot Mass: 2350 kg• Structure: KR 500-2• Mounting: Floor• High payload and large

work envelope • Extension of the

reference load center distance

• Integrated energy supply• Efficient use of floor

space

Fanuc S-430iW Robot• Axes: 6• Payload: 165 kg• H-Reach: 2643 mm• Repeatability: ±0.3

mm• Robot Mass: 1300 kg• Structure: Articulated• Mounting: heavy-duty

floor mount• Slim arm and wrist

makes parts accessible and fast speeds reduce cycle times

• Uses Fanuc Servo Drive System, resulting in fast point-to-point positioning

IRB 6620New competitive robot for the automotive industry by ABB

• Economical and Compact

• Can also work bending backwards and has a large downward working area (semi-shelf)

• Use of Electronic Position Switches(EPS)

• Reach: 2.2 meters• Payload:150 kilos• Weight: 900 kilos. • Absolutely the lightest

robot in its class

IRB 6620 – The agile spot welder

Thank You