ComauFlex BIW Plant Strategy - Thailand Automotive · PDF fileMade in Comau ComauFlex BIW...

Made in Comau

ComauFlex

BIW Plant Strategy

Bangkok, June 23rd, 2016

Xiaowei TAO

Manager, GSD Dept, Body Assembly,Comau China

Made in Comau Property of Comau - Duplication prohibited 2

• Comau General

• What is ComauFlex

• Systems & Solutions

• Products

• Projects with Aluminium Joint

Index


1995 - 97 Comau opens plants

and offices in Germany,

Brazil, Argentina, France

and India

1998 Establishment

of Comau Service

Comau Poland is established

1999 Comau acquires Renault

Automation in France

and Pico in USA, Mexico,

Germany and UK

1973 Several companies

in the Turin area create

COnsorzio MAcchine Utensili

1977 Establishment of Comau

Industriale with

powertrain and body

(welding, assemby and

handling) divisions

1978 Comau S.p.A.

is established

incorporating Comau

Industriale activities

2009 Establishment of

Comau Aerospace

2000 - 03 Comau China, Romania

and Russia are established

2010 Establishment of

Comau Adaptive Solutions

and eComau

2014 Comau Czech and

Turkey are

established

Comau opens office in

Munich (DE)

Comau Mexico

expansion

2013 Comau China in expansion:

3 new sites

Kunshan, Shanghai,

Dalian

2015 Comau Thailand

is established

Comau

São Paulo (BR)

is established

History_Over 40 years of experience in Automotive

Made in Comau Property of Comau - Duplication prohibited

4

Comau in the World

Made in Comau 4

USA

MEXICO

BRAZIL

ARGENTINA

SPAIN

FRANCE

UK

GERMANY

CHINA

THAILAND

RUSSIA

TURKEY

ITALY

POLAND

ROMANIA

CZECH REPUBLIC

INDIA

Property of Comau - Duplication prohibited


Heavy industry Energy Defense

Commercial vehicles

Aerospace Automotive Commercial vehicles

Business Scope


2012-15 Revenues (MIO €)

2015 Turnover per area (%)

2012 2013 2014 2015

1,950

1,550 1,464 1,450

Key Figures


• Comau General



• Products


Index


What is A flexible BIW manufacturing strategy

Traditional Factory Engineered Factory

We deliver the Best Value to our customer

• Logistic Optimized

• Model change simplify

• High Speed Transfer

• Modular Architecture

• Compact footprint

• High density welding


9

Major Subs

&

Mainlines

Material Staging Zone

Marketplace Part Loading

&

Minor Subs

Part Loading Zone

Material Entry Zone

Quality Zone

ComauFlex Overview Manufacturing Strategy


10

Maintenance

Production

Material Handling

- Fork-lift

- Tugger

ComauFlex Overview Direct/Indirect Labor


11

VersaRoll

VersaPallet Fro

nt

Str

uc

ture

an

d R

ea

r F

loo

r

Un

de

rbo

dy F

ram

ing

Fro

nt

Flo

or

an

d s

ub

as

sy

Un

de

rbo

dy R

e-s

po

t

Bo

dy S

ide

Ou

ter

Le

ft

Bo

dy S

ide

In

ne

r L

eft

Up

pe

r B

od

y F

ram

ing

Bo

dy S

ide

Ou

ter

Rig

ht

Fra

min

g R

e-s

po

t

Fro

nt

an

d R

ea

r R

ail

s R

/L

Bo

dy S

ide

In

ne

r R

igh

t

ASSEMBLY ZONE

MATERIAL ZONE

ComauFlex Overview Example


Floor Plates BRIC Legs

Shipping Modules

ComauFlex Overview Example

12

Integrated Lines

COMAU VERSA Subs_2016324135928.wmv


Welding Guns

Vision Systems

Break-Away

Pallet Transfers

Pallet Tooling

Logistics-SPD

Line Feeding Devices Roller Heming

AGC

APC

13

How to be ComauFlex Modular Strategy

VersaPallet

OpenGate VersaRoll


• Comau General



• Products


Index


VersaRoll System


VersaRoll System

For Return

All carbinet upstairs

Simplify cable/wiring connection

Tool tray

Space on floor to be extended

COMAU VERSAFLEX_2016324135349.wmv


VersaPallet System


VersaPallet System

For Return

All carbinet upstairs

Simplify cable/wiring connection

High Desity

Robot

Welding


Opengate System


Opengate System

Open RoboGate ®

up to (6) Models

Key Features:

Up to (18) Welding Robots

Integrated solution for cabinets

Scalable investment

Up to (6) dedicated gates

Since 2010,

70 stations install in China

With 185 gates

Phase 1 Phase 2

Phase 3 Phase 4 Phase 5

Opengate.avi


• Comau General

• What is Comau FLEX


• Products


Index


Geo Pallet with Power Roller Bed

For Geo For Respot For Facility

• NO Air Supply

• NO Shim Adjustment

• NO Wiring

• NO Piping

• ±0.1mm Repeatability in X/Y/Z

• 6.0s for horizontal transfer

• 1.5s for pallet up

• 1.5s for pallet down

TOLERANCE X ± 0.1mm

TOLERANCE Y ± 0.1mm

TOLERANCE Z ± 0.0mm(touch)

TOLERANCE X ± 0.5mm

TOLERANCE Y ± 0.3mm

TOLERANCE Z ± 0.5mm

• 6.0s for horizontal transfer • 6.0s for horizontal transfer


Compact Gun Family_For Steel

+

+

• NO casting component

• Al Alloy Body 7075

• Common servo motor and transformer

• Weight 65~90kg

Force up to 440 daN

Force up to 700 daN

• Al Alloy Arm 7075


Compact Gun Family_For Steel

Robot Payload

90~110kg

• Less Space

• More Faster of movement

• Smaller Robot

• High Desity

Gun Weight

65~90kg

COMAU Compact_gun.mp4


Compact Gun Family_For Aluminium Ducker Worldwide Aluminum in cars, 2015

Aluminum Body and Closure

(% of Volume)

Mark

et

Sh

are

(%

of

pie

ces)

2015 Ducker Worldwide

Automaker Survey

Compact High Force

• Weight 110 ~ 130 kg

• MFDC Transformer 255 KVA at 50% DC

• Welding Force X-Gun 600 daN

C-Gun 704 daN

• Actuator (Inverted roller screw)

X-Gun 1764 daN

C-Gun 704 daN

• Software equalizing (COMAU, KUKA, ABB, FANUC)

• External load washer with amplifier for force feedback


Compact Gun Family_For Aluminium

Real Applications Test In House

Result Achieved:

Tip dressing each 24 spots – Electrode life up to 2600 spots


RecogoniSense System(Vision)

RAIO = RecogniSense All-In-One

3D Camera Processer

LED

Light

Recognition process time: < 300 ms

Rack position: +/- 75 mm X, Y, Z

+/- 5° Rx, Ry, Rz

System Accuracy: +/- 0.5 mm X, Y, Z

VOV(Volume of View): Min 50mm x 50mm x 25mm

Max 2400mm x 1200mm x 600mm

Resolution X/Y/Z: +/- 1.0 mm @ Max VOV

+/- 0.1 mm @ Min VOV

Resolution Rx/Ry: +/- 0.2 degrees

Resolution Rz: +/- 0.1 degrees

Key Features



Traditional + + +

Rack Operator Centering Tooling Robot+Gripper

With RAIO

Rack

+

Robot+Gripper+RAIO

>>>>>>>> NO operator

>>>>>>>> NO centering



Bodyside Outer Loading

From normal rack

VERSAFLEX_2016324165617_201632416586.wmv


• Comau General



• Products


Index


Projects with Aluminium Joint in China

Customer Plant Model Scope Production Capacity Joint Technology

1 Jinqiao China O11 Framing Inner;Framing

Outer;Sunroof;Respot Line 10JPH

RSW/SPR/FDS/Al Laser

Brazing/Al Hemming

2 Changshu China X261 UB and UB sub 16.4JPH SPR

3 Hangzhou China CD539 Hood 20JPH SPR

4 South Plant China E15/E16 Hood/Decklid 27JPH Clinch/Al Hemming

5 SGM South Plant China A10 Hood 15JPH Clinch/Al Hemming


Projects with Aluminium Joint in China

1 2 3

4 5 SPR

FDS

Made in Comau

Via Rivalta, 30 - 10095 Grugliasco - Torino ITALY - www.comau.com

Thanks

For your Attention

http://www.comau.com

ComauFlex BIW Plant Strategy - Thailand Automotive · PDF fileMade in Comau ComauFlex BIW...

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