What is the most expensive piece of glass in a car?
It is particularly important that the corner windows are tightly fixed to the car body. At present, a large number of car companies use the method of priming glass first and then coating glass glue.
Primer is a common pretreatment process that directly affects the subsequent bonding reliability.
1. Pain points of traditional artificial primer operations
1. The production efficiency of manual operation is low and the cycle time is long.
2. The manual operation application trajectory is unstable, the strength is uneven, the primer consistency is insufficient, and it may also cause repeated application and missing coating.
Second, customer needs
The customer's production line has a high degree of automation, and the original corner window primer and handling process are carried out manually, but there are also industrial robots to cooperate. The customer hopes that through the introduction of collaborative robots, it can meet the needs of small space deployment and operation, further shorten the production cycle, improve production efficiency and quality, and improve the automation and flexibility of the production line. At the same time, customers have high requirements for robot safety and operational stability.
03 Solution
The whole set of primer handling equipment is controlled by PLC, and the card-saving robot communicates with PLC (Modbus TCP) to realize automatic one-button start.
Process
1. Manually place the product at the primer station
2. The primer coating process is carried out by the JAKA Zu 5s cobot
3. The equipment module automatically bakes the product
4. At the end of baking, the products are picked up and handled by the JAKA Zu 12 cobot
The JAKA Zu 5s cobot is working on a primer
One JAKA Zu 5s cobot was responsible for priming two corner windows, and the customer had two different sizes of corner windows. According to the different sensor signals received, the robot judges the size and number of windows, runs different sub-programs, and flexibly switches for primer operations.
Due to the manual feeding of the production line, high requirements are put forward for the safety of collaborative robots. The JAKA Zu 5s cobot has its own six-dimensional force control sensor, which can sensitively detect collisions and pause; When the collision disappears, the robot can continue to operate, ensuring the safety of personnel. Jieka Robot is the first enterprise in the collaborative robot industry to obtain MTBF (Mean Time Between Failures) certification of 80,000 hours, and its products are stable and reliable.
The JAKA Zu 12 cobot is carrying out handling work
In the handling process, due to the large number of surrounding interference mechanisms and the very small space of the material level, the robot needs to be able to flexibly adjust its attitude and cannot move significantly. At the same time, the robot should load the weight of objects such as corner windows, grippers, and cables under the condition of its own small size.
The JAKA Zu 12 cobot has a high load-to-weight ratio to meet the customer's needs, integrating a gripper with suction cups to grab the corner window from above and flexibly flip it in a small space to complete the handling and unloading.
Fourth, the effectiveness of the project
1. Shorten the cycle time: the CT of the manual operation of the original production line is 120s, and the CT is 90s after the introduction of the card-saving robot, and the efficiency is increased by 25%.
2. The original station requires 2 manpower for a single shift, but now only 1 manpower is needed for a single shift, saving 50% of labor costs for a single shift.
3. Ensure the accuracy of primer trajectory and coating uniformity, improve product consistency, and ensure product quality.
The 4-section card robot replaces manual operation, has a low threshold for one-button start operation, and enhances the degree of automation between equipment, reduces human intervention, and improves the automation, flexibility and intelligence level of the production line.
5. Expand applications
The Jie Truck Robot Primer Handling Solution has high production efficiency, flexible deployment, simple operation, strong safety, high stability, and can realize automatic product changeover, and can be widely used in the assembly of parts of different shapes and sizes such as corner windows, windshields, automotive interior parts, and frames.
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