Conveying car parts efficiently in a robot cell

Task

Compact conveying solution for bulky car body parts through a robot cell

Vehicle manufacturers fit side impact beams in the car body to ensure that drivers are protected as much as possible in the event of a lateral impact.In order that these elongated metal reinforcements cause as little vibration and noise as possible in everyday life, they are generally coated with a damping material. In many cases, this process is automated nowadays. In a robot cell, the side impact beams are transferred to a granulating machine and removed. A complex process, in which the precise interaction of numerous automation components is vital.

A crucial factor is, for example, the conveyor technology which supplies the side impact beams to the cell in a cycled manner and transports them away again after processing. However, finding a suitable supplier proved to be a challenge for the manufacturer of this robot cell. This is because the conveyors not only have to position the beams, which are up to 1,250 mm long, with repeat accuracy and precision so that the robot can pick them up. They also need to be able to buffer twelve components so that employees can move freely and the line can temporarily run autonomously. Finally, the conveying path needs to be as compact as possible and at the same time adaptable so that at the end, a seamless transfer to a customer-side conveyor offset by 90° can be achieved.

The manufacturer found the right partner for this challenge with mk. The experts at mk have realised an individual conveying path that meets all requirements.

Solution from mk

Space-saving circulation system for seamless material flow

mk has implemented two individually configured conveyor systems. An SPU 2040 accumulating conveyor, a 5,500 mm long and 800 mm wide, two-track chain conveyor with aluminium pallets, transports the parts into the robot cell. The pallets of the left and right tracks are connected by a strip, forming a rigid and stable connection. In addition, the pallets are fitted with wear strips, positioning grooves and bushings as well as a drilling pattern for the customer’s workpiece holder. The corresponding sensor system allows the precise stopping, separating and positioning of the pallets at a cycle time of approximately 30 seconds. The workpieces are manually placed on the pallets of the SPU 2040 by a worker. After removal by the robot, the beams then travel back to the starting position on the underside of the conveyor. This creates a space-saving circulation system that allows up to twelve side impact beams to be buffered –eight products are outside the protected area and another are four inside. Additional conveying levels or complex lifting and lowering mechanisms are not necessary.

After granulation, the robot places the side impact beams on another conveyor system from mk: a ZRF-P 2040 dual-line timing belt conveyor, 5,600 mm long and 500 mm wide, with customer-supplied workpiece holders on the top side of the timing belt. The solution boasts one special feature – at the end of the conveying path, mk has fitted a compact GUF-P Mini belt conveyor between the two lines, 400 mm long and 200 mm wide. The cross conveyor lifts the side impact beams with a pneumatic lifting device and transfers them to a belt conveyor provided by the customer. This realises the 90° corner transfer.

Thus, a continuous and compact material flow solution has been developed that reliably buffers the side impact beams, delivers them to the robot in a cycled manner and discharges them safely after processing.

Benefits for the customer

  • Flexible buffering: Accommodation of up to twelve components relieves employees and keeps production running smoothly.
  • Precise robot supply: The SPU 2040 positions long components up to 1,250 mm in length in a precise and cycled manner.
  • Space-saving feed: The circulation system for pallets eliminates the need for additional conveying levels.

Products used

> Two-track accumulating conveyor SPU 2040
> Dual-line timing belt conveyor ZRF-P 2040
> Belt conveyor GUF-P Mini

 

  • Puffern und getakteten Zu- und Abführen von Karosserieteilen
  • Puffern und getakteten Zu- und Abführen von Karosserieteilen
  • Puffern und getakteten Zu- und Abführen von Karosserieteilen
  • Die Werkstückträger des SPU 2040 fahren auf der Unterseite des Förderers zur Ausgabgsposition zurück
  • Zweistrang-Zahnriemenförderer der Serie ZRF-P 2040 mit Hubeinrichtung
  • GUF-P MINI als Hub-Querförderer integriert in einen Zweistrang-Zahnriemenförderer der Serie ZRF-P 2040
  • Puffern und getakteten Zu- und Abführen von Karosserieteilen
  • Puffern und getakteten Zu- und Abführen von Karosserieteilen
  • Puffern und getakteten Zu- und Abführen von Karosserieteilen
  • Die Werkstückträger des SPU 2040 fahren auf der Unterseite des Förderers zur Ausgabgsposition zurück
  • Zweistrang-Zahnriemenförderer der Serie ZRF-P 2040 mit Hubeinrichtung
  • GUF-P MINI als Hub-Querförderer integriert in einen Zweistrang-Zahnriemenförderer der Serie ZRF-P 2040