Bonding, welding, riveting on 20 m² and fully automatic - IBG's latest multifunctional robot cell is a true all-rounder in component assembly.
An average car today consists of up to 10,000 individual parts. Depending on the size and equipment of the vehicle, it can also be more. The carmakers source almost all the required parts from specialized suppliers around the world: brakes and tires, coolers and pumps, steering wheels and headlights, radios and navigation equipment, and chassis-specific components.
Such chassis-specific components also include supposedly inconspicuous stabilization components, which serve for optimal force transmission, best vehicle comfort and safety.
These aluminum components, consisting of various extruded sections and die-cast joints, must be assembled in a quality-assured manner. Different types of assemblies for vehicles with left-hand or right-hand drive vehicles must be observed. Another challenge for IBG on the part of the customer was the need to be able to process further components on the system and a generally limited amount of space.
IBG has met this demand and successfully implemented it within the framework of a multifunctional robot cell. Within this cell, various joining processes are implemented in a quality-assured manner for assembling the components with collaborating transfer points. Basically, the components are to be glued, at the same time there is a requirement for additional fixation by means of spot welding and the introduction of press-in nuts and a clear marking of the components.
After scanning the production order with a barcode scanner, the employee places the components in special holders mounted on an H-turner. A camera system checks whether all components have been inserted correctly.
Then the robot picks up the components provided by an H-turntable with a multi-gripper and guides them within the cell to the clamping fixtures in a defined manner. At the same time adhesive beads are automatically applied to the adhesive surfaces, whereby these adhesive beads are 100% controlled by means of a scanner for quality assurance. The robot then assembles the components professionally. Curing of the adhesive takes place in a separate oven outside the plant.
In order to ensure safe removal from the clamping device before curing, the robot uses its multi-gripper to pick up a welding gun and fix the components with defined spot welds. Finally, each component is still clearly marked with a scoring marker.
Within this multifunctional robot cell, it was possible to integrate a wide variety of joining methods such as bonding, welding and riveting in a small space.