Advanced Manufacturing: Robotic Technology and Automation

Advanced Manufacturing: Robotic Technology and Automation

Summary

At present a Car Company manufacture a part of an automobile suspension assembly known as a Crosstube. They are considering moving from manual to robotic production in either a single cell/single robot or line/multi robot layout. The following report recommends the use of the Fanuc Arc Mate robot, which is a compact, six axis, modular-built, electric servo-driven robot which is controlled by the a R-J3 controller with ArcTool application software. All ancillary equipment options are considered.

The two layouts are considered and all health and safety implications are detailed. The report concludes with a discussion on the validity of each layout. For low volume manufacture it is recommended that a single-cell layout is utilised. For economic production of high volumes a line layout would be the primary choice.

Contents

1.0 Introduction

2.0 Robot Specification

2.1 Mechanical Characteristics

2.2 Performance Specifications

2.3 Programming & Control Methods

3.0 Specification Of Ancillary Equipment

3.1 Welding Tool

3.2 Gripper

4.0 Robotic Assembly

4.1 Cell Layout

4.1 Line Layout

5.0 Health and Safety

5.1 Cell Layout

6.2 Line Layout

6.0 Discussion

7.0 References

8.0 Appendix

1.0 Introduction

BL Cars Ltd manufactures a part of an automobile suspension assembly. It is known as a Crosstube. The complete part consists of four thin sheets of steel presswork. Two parts are identical and are positioned either end of the larger cross brace, which has been formed from two larger pieces of sheet steel..

Presently the two parts making up the cross brace are secured using specific jigs. Once secure they are spot welded along the flange edges. The next step is to secure the two mounting plates to the presswork. The process is completed by arc welding the component to add extra strength to the spot welds and secure the mounting plates. N.B. When the parts are pressed from the sheet steel locating points are incorporated. This ensures each part is located in the correct position in the jig.

The use of industrial robots is ever increasing. The robot usually does a secondary machinery operation after a primary shaping operation. When performed manually, this secondary operation often requires the operator to work in an unpleasant environment, to carry out a repetitive and tiring task with bulky tools.

BL Cars Ltd is considering using robots to automate the Crosstube assembly process. The robots will be used for material handling, spot and arc welding in one of two contrasting layouts:

1. Single-cell, single robot -- low volumes

2. Line-layout, multi-robot -- high volumes

Compared to manual welds, robot welds provide the following benefits:

· A higher quality weld

· Greater consistency

· Increase arc on time as a proportion of total time

· Increased operator safety

· Automatic weld quality monitoring.