Linear floor tracks enable robots to execute multiple processes for truck sidestep assembly

Situation

For automotive original equipment manufacturers (OEMs), hard tooling is a continual roadblock to efficiency and speed to market. Given wide variation among makes, models, and even same-model components, every model change involves the potential need for new manual processes and custom-designed tools. Vision-guided robots offer the flexibility necessary to side step many of those tooling and fixturing requirements.

However, for complex assemblies requiring many process steps and workcells, the need to transfer parts between workcells can become cost- and space-prohibitive.

An OEM of side-step rail assemblies for passenger trucks had a manual, hard-tooled system that was ill-equipped to handle product variation. This resulted in significant downtime and manpower requirements.

Resolution

Factory automation systems provider BOS Innovations set out to address both these concerns for the manufacturer by developing a workcell that mounts robots on floor tracks, reducing robot count while boosting functionality.

To replace the OEM’s manual tooling system with vision-guided robots, BOS decided to use FANUC robots and vision products along with ATI tool changers and Güdel TrackMotion Floor track modules for flexibility and space efficiency. In this new system, five vision-guided M-710 robots carry out various rail assembly processes, including riveting and bracket assembly. Combined with the tool changers for swapping out end-of-arm tooling (EOAT), these robots have all but eliminated the OEM’s complex geometric tooling and fixtures.

Conveying the rails from one workcell to the next are two R-2000 robots, each mounted on linear floor tracks. By transferring, rotating, and aligning rail assemblies, these track-mounted robots help reduce the costs and complexity of the system, even in an application involving large parts and complex station layouts.

The system achieved a cycle time of 30.5 seconds per part and a throughput of 547,000 rail assemblies per year. The elimination of hard tooling also has resulted in lower operating costs and greater quality, throughput, and flexibility.

Güdel Inc. www.us.gudel.com