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Stellantis N.V. is a Dutch multinational car producer established by way of a merger between PSA and Fiat Chrysler Vehicles. The corporate put in 11 collaborative robotic arms from Common Robots (UR) at its Mirafiori manufacturing facility in Turin, Italy, to automate a sequence of complicated meeting line operations and qc for the brand new Fiat 500 electrical automotive.
The collaborative functions developed at Mirafiori have delivered vital advantages when it comes to working precision and high quality, and likewise improved the ergonomics of a sequence of operations beforehand carried out manually.
Problem
On the Fiat 500 electrical automotive manufacturing line, a few of the meeting processes and qc required the introduction of particular automation applied sciences to make sure the standard and repeatability wanted to satisfy product requirements. Moreover, given the pretty excessive common age of the manufacturing facility staff, the query of ergonomic well-being was additionally a problem.
Answer
Stellantis determined to undertake UR cobots robots some years in the past. Collaborative automation has freed operators from repetitive and bodily demanding guide duties, in order that they are often employed on processes with larger added worth.
The 11 UR cobots now automate the next functions:
- Utility of the waterproof liner to the automobile doorways (2 UR10e cobots working in parallel)
- Positioning of the soft-top (activation of the primer observe and visible inspection to make sure the right extrusion of the adhesive band across the perimeter) (1 UR10e)
- Verify on soft-top body dimensions (1 UR10e)
- Riveting of the tailgate with blind rivets press-set on the boot body (1 UR10e)
- Hood mounting (1 UR10)
- Tightening of the rear side-door hinges (1 UR10)
- Mudguard mounting (2 UR5 and a couple of UR10 cobots)
The UR cobots on the Mirafiori manufacturing facility had been rolled out progressively to allow the operators to totally perceive how the automated processes labored.
“As a primary step, we determined to introduce a UR cobot within the firm canteen, distributing glasses of water to staff throughout the lunch break,” Mirafiori plant supervisor Luigi Barbieri mentioned. “This gave the road staff the chance to see the protection and collaborative nature of the cobots for themselves, and overcome any apprehensions concerning the security of the next functions.”
Outcomes
After the success of this preliminary trial, the UR cobots had been put in on a sequence of functions on the five hundred electrical automotive manufacturing line:
Utility of the waterproof liner to the automobile doorways: Two UR10e cobots function in parallel on the door meeting line. A imaginative and prescient system registers the arrival of the door and prompts the cobot, which makes use of a curler connected to its wrist to use fixed strain on the material, making use of it on the door panel.
The applying is especially difficult as a result of it requires the cobot to observe a posh path inside a confined area, avoiding the panel’s push pin protrusions and guaranteeing that the liner is totally sealed to forestall the infiltration of water. The cobots work with millimetric precision, guaranteeing a repeatability of +/- 0.05 mm.
“The UR cobot has considerably improved the ergonomics of this software,” mentioned ergonomics specialist Giuseppe Guidone. “The applying of the liner required the operator to use fixed strain utilizing a dynamometric curler, a process that over the long run might harm the arm joints and trigger musculoskeletal illness. So the cobot has introduced two advantages: excessive working precision and high quality, together with improved ergonomics and well-being for our operators.”
A UR10e cobot makes use of a curler connected to its wrist to use the material to the door panel. | Credit score: Common Robots
Tender-top meeting
Two UR10e cobots function on the soft-top meeting line for the Fiat cabrio 500 mannequin. The primary cobot performs two completely different operations; Utilizing a pad supported by a particular pick-up machine, the UR10e cleans and prepares the primer observe, on which the adhesive to repair the soft-top to the body is subsequently utilized. The second operation is a high quality management, the place a imaginative and prescient system checks the geometric continuity and dimensions of the adhesive band. The second cobot works in synergy with an anthropomorphic robotic.
As soon as the soft-top has been assembled, it’s opened on a particular help after which picked up by the robotic. At this level, the second UR cobot runs a measurement verify (by way of a imaginative and prescient system) on the soft-top body to make sure the conformity of the scale. As soon as conformity has been ascertained, the soft-top is faraway from the road by the anthropomorphic robotic.
This software gives a sequence of productiveness and high quality benefits. The cobots be certain that the adhesive extrusion is right and verify the scale of the soft-top body.
Tailgate riveting
On the door meeting line for the Fiat 500 electrical automotive, a UR10e cobot has been configured to press-set 10 blind pop rivets, which safe the boot hinge reinforcements to the boot body. The operator masses the tailgate body and hinge reinforcements onto the workstation, then leaves the cobot to place and press-set the rivets.
The applying offers productiveness and ergonomic advantages. On the identical time, fixed monitoring of the workstation enter and output parameters ensures greater and constant course of high quality.
Hood mounting
For this software, the automotive physique reaches the workstation with the hood mounted in a closed place and the hinge screws inserted by the operators on the earlier station. As soon as the hood geometry has been established, the cobot (a UR10) strikes into place and tightens the 4 screws to the right torque.
The principle benefits of this software are high quality, effectivity and ergonomics, provided that the hood reaches the station in a closed place, making right tightening extraordinarily tough. Because the hinge screws to be tightened aren’t seen, the operator might simply miss one or make an incorrect tightening. The cobot additionally improves the ergonomics of the operation, releasing the operators from working in uncomfortable or awkward positions.
Two UR5 and two UR10s cobots are put in on a platform that lowers itself on the z axis in relation to the physique. The wings of the platform shut to repair the geometry and activate the tightening operation on the 24 screws that fasten the mudguards. | Credit score: Common Robots
Further door hinge tightening
For the Fiat 500 mannequin that includes an additional rear aspect door, an automatic software able to performing a posh tightening cycle was required. With the help of a sophisticated automated device on which the cobot is put in, the door is positioned appropriately on the automobile physique. The cobot then performs the tightening operations, from the rear of the boot.
The cobot meets two completely different course of necessities: it frees the operator from tightening the hinges in an ungainly posture, the place they might be unable to see the right positions contained in the automotive physique; and it prevents the kickback from the tightening device (which operates with a 75 Nm torque) hitting the arm of the operator.
Mudguard mounting
On this station on the sheet steel line, the body arrives with the suitable and left mudguards already in place. Two UR5 and two UR10s cobots are put in on a platform that lowers itself on the z axis in relation to the physique. The wings of the platform shut to repair the geometry and activate the tightening operation on the 24 screws that fasten the mudguards. Every of the 4 cobots is fitted with an computerized screw gun with torque management.
The applying gives varied benefits. Collaborative automation ensures ergonomic advantages for the operators (who’re now not required to work under the automobile physique). Because the screws are torque tightened, tensile stress on the sheet steel elements is eradicated. Additionally, the cycle time is shortened, boosting the productiveness of the entire station.
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