In the automotive lamp industry, the uncertainty of market demand is gradually increasing, the degree of customization is constantly improving, and multi-variety and small-batch production are gradually replacing large-scale production. Manufacturers need to have the ability to respond to market demand in a timely manner in order to occupy the corresponding market share in the fierce competitive environment.
The customer is a leading enterprise in China's automobile lamp assembly, and its products mainly include automobile headlights, rear combination lights, fog lights, daytime running lights, indoor lights, atmosphere lights, etc. The products are mainly matched by major well-known automobile brand companies, and product quality and supply capacity are particularly critical.
With the disappearance of the demographic dividend, in order to cope with the changing market demand, the customer decided to transform and upgrade the production line, through the introduction of more flexible collaborative robots, improve production efficiency, and achieve rapid production changeover.
solution
In the lamp screw locking process section, based on the needs of customers, Jieka proposed a flexible intelligent screw locking solution, and took the lead in realizing robot substitution.
The project is equipped with two JAKA Zu 7 collaborative robots, with a self-weight of 22 kg, a payload of 7 kg, and a working radius of 819 mm. A pallet is placed on the left and right sides of the workbench, and through the conversion of the tray and the running program, as well as the working mode of man-machine integration, rapid production change can be realized, giving full play to the flexible intelligence of the card-saving robot.
Due to the limited space for production line transformation and the limited space for robot movement, there may be a risk of collision with other equipment. And the robot transition points should not be too many, otherwise the interval time is too long, and the requirements for improving efficiency cannot be met.
By adjusting the lock attitude and angle, the clip card reduces unnecessary transition points, so that all points move in a straight line to ensure that each point will not collide when it returns to the initial position. At the same time, by increasing the tempo, the whole process of completing the nail sucking, lifting up, moving to the locking point, completing the locking, and returning to the initial position can be achieved in an average of 3 seconds, so as to achieve efficient locking.
It has been calculated that the number of lamp assemblies completed by the workstation per day has nearly tripled compared to manual work. At present, the workstation has been replicated in the automotive lamp industry, efficiently helping customers in flexible and intelligent production.
Due to the particularity of the locking process, accuracy and stability are the two technical indicators that customers pay the most attention to when introducing cobots.
With an accuracy of ±0.02 mm, the JAKA Zu 7 cobot is perfectly matched to the customer's needs. Based on the strict control of product quality, the customer puts forward higher requirements for the stability of the robot. Before each robot officially enters the customer's production line, in addition to the manufacturer's own test, it also needs to complete an additional 5,000 screw lock test, and the NG rate is less than 3/1000 to be considered qualified. This test directly intercepted the vast majority of manufacturers from the door. The Jieka collaborative robot, from the first to enter the customer's production line, to the current thousands, has been highly recognized by customers in actual combat.
The cooperation between the card and the customer is getting closer and closer, in addition to relying on the "hard shell" products of the card, but also thanks to the high-standard technical service "iron army" of the card. From project testing to delivery, and even now the production line is completely autonomous and normal operation, Jieka has always had a professional project service team stationed in the customer's factory to train and guide the customer's technical team.
The drag-and-drop programming and graphical programming technology of the card greatly reduces the threshold for the use of the robot, making the card saving collaborative robot simple and easy to use.
With the two-way support of products and services, customers' trust in the festival card has been rapidly improved. Customers reported that if the workstation fails, their first reaction is that there is a problem with the screw machine, not a problem with the cobot.
It is an inevitable development trend for the production of the automobile industry to be flexible, flexible, intelligent and informatized. The tacit cooperation between the card and the customer also wins more business opportunities for the customer. Due to the timely delivery and stable quality, the customer has been rated as an "excellent supplier" by many OEMs.
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Screw lock - section card
Application features:
The operation of the robotic arm of the small assistant robot is fast and sensitive;
According to the requirements of the lock screw product, the appropriate torque adjustment range is configured, and the torque can be adjusted separately for each axis;
High efficiency, high stability, high quality, to achieve high intelligence, unmanned operation of lock operation.
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