Robotic lines will soon generate 75% of vehicles. Automakers, pioneers in automation, utilize robotic arms in car manufacturing to improve accuracy, efficiency, and safety. These robotic systems' welding, painting, and assembling precision is unmatched. Additionally, robotic vision, AI integration, and force-sensing technologies have altered material handling and quality control. Therefore, robotic arms in vehicle manufacturing are necessary for high output, construction quality, and operating safety.
Evolution of Robotic Arms in Car Manufacturing
General Motors introduced the first industrial robot for spot welding in the 1960s, starting the development of robotic arms in car manufacturing. Mercedes-Benz and BMW debuted robotic painting and finishing in the early 1980s, but expense and complexity delayed advancement.
By the 2000s, significant milestones were made, including switching from hydraulic to electrically powered robots, doubling speed, and optimizing route accuracy from ±25 mm to ±0.1 mm. Contemporary 6-axis articulated robotic arms with vision systems and force sensors are used for accurate welding, painting, and material handling.
Types of Robotic Arms Used in Car Manufacturing
Six-Axis Articulated Robots: Six-axis articulated robots dominate automotive manufacturing. They have six degrees of freedom and can accurately perform welding, assembly, and material handling. Moreover, their maneuvering in 3D space allows for precise operations in confined areas like engine compartments for better application range.
Collaborative Robots (Cobots): They work alongside human operators and other robots with easy integration into assembly lines. They can accomplish screw driving and windshield installation with high precision. Furthermore, their safety features and force-limited operation allow them to interact with humans for greater productivity.
Specialized Robots for Painting and Finishing: Specialized robots for painting and finishing provide high-quality coatings. They utilize atomizing bells and electrostatic paint systems for uniform paint application with negligible waste. Besides, robotic vision and AI-based inspection system progressions enable these robots to discover and correct defects in real-time for superior finish quality.
Applications of Robotic Arms in Car Manufacturing
1. Welding
Robotic arms in car manufacturing are vital for welding. Spot welding heavy body panels demands a high payload and extended reach. MIG and TIG arc welding need precision torch placement for consistent, high-quality welds. Collaborative robots with bigger industrial robots to correctly place panels for welding boost efficiency. More efficient than 20% of trained humans, these systems can reach 85% with precise tolerances and low error rates.
2. Assembly
Automotive robotic arms shine in high-speed assembly. They precisely handle motors and pumps. Robots gently drive screws, attach wheels, and install windshields for quality. Delta robots can assemble 300 pieces per minute for greater throughput. Such automation keeps assembly lines running effortlessly to lower cycle times by 20-30%.
3. Painting, Sealing, and Coating
Robotic arms in car manufacturing apply paint precisely. They minimize thickness fluctuations and waste. Contemporary systems may apply two-tone paint and individual graphics in one pass with 100% transfer efficiency. The robots spray adhesives, sealants, and primers accurately while utilizing less material and improving environmental compliance. It saves over 0.5 liters of paint each car.
4. Material Handling and Part Transfer
In auto production, robotic arms competently move components. Loading and unloading CNC machines lowers slowdowns and human interaction. The robots can handle weights up to 2-2300 kg and render safe and accurate material transport possible. Robots pour molten metal in foundries to decrease human risk. This automation helps boost plant productivity.
5. Material Removal
Robotic arms in car manufacturing remove materials well. They trim flash from plastic molds and polish them. Such robots maintain pressure using force-sensing technology for quality. They cut fabric and other materials well because they can repeat intricate pathways thousands of times without variation. It cuts trash and promotes product quality.
6. Internal Logistics
Car manufacturing robotic arms use AMRs and autonomous vehicles for internal logistics. Such systems optimize workflow while transporting raw materials and components from storage to production. For example, AMRs have replaced manual material delivery to welding stations at Ford. They effectively traverse production layouts to eliminate human error and optimize plant logistics. Automated pallet-handling technologies decrease shipping processing time by 50% for some groups.
Technological Advancements in Robotic Arms
Technological advancements in robotic arms in car manufacturing have enhanced reliability and flexibility. Robotic vision systems include laser and camera arrays on robotic arm wrists for real-time feedback and accurate component installation, including door panels and windshields. Force-sensing technology lets robots cut and polish plastic molds with consistent pressure to preserve quality and avoid waste.
Offline modeling and programming using CAD models are routine for engineers to improve robot motions and collision avoidance before deployment. Similarly, BMW's Regensburg facility uses AI-controlled inspection and sanding robots that utilize deflectometry to identify paintwork variances and train flexible robots to sand and polish specified areas for better finish quality and lower rework.
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