Motor Vehicles

Case Studies

1) Vision Sensors Improve Pickup Truck Part Handling At Daimlerchrysler (pdf)

At the DaimlerChrysler Stamping Plant in Twinsburg, Ohio, an automated process of handling stamped truck-bed parts was needed for the company's full-sized Dodge pickup truck production. Without automation, the 6 ½' and 8' box-side inner parts for 2002 Ram trucks would need to be handled by operators. The operators, working side by side in the cell, would have to unload a rack of 18 parts, carry each one over to another station, and place onto a fixture. However, there were a number of problems with this approach.

2) Robot Park in Body Shop (pdf)

In the body shop of the Ford plant in Cologne-Niehl, Germany, robots have to able to produce any of the possible variants of the Fiesta. Moreover, they must also be capable of assembling two different underbodies at the same time, while at the same time introducing a third variantinto the line. This parallel introduction will allow Ford to change from one variant to another without interrupting production, thus avoiding stoppages. In addition, 100 percent flexibility will make it possible to vary freely the sequence and relative proportions of the different versions of the Fiesta models, and production will be able to respond even more quickly to customer wishes.

3) Welding of Automotive Front Ends (pdf)

Automotive supplier Läpple produces front ends for the DaimlerChrysler Mercedes CLK, among other things. Läpple's fast-paced environment – with three-shift operation and "just in time" contracts – demands precise welding processes and permanent availability.

4) Welding of Aluminum Vehicle Bodies (pdf)

Given the interlinked operations of supplier plants of the AIXAM MEGA Group, of which CARmetal is a member, the company has to provide a specified number of body frames per day. For this reason, and due to rising production volume, the car manufacturer wanted to invest in a state-of-the-art robotic cell. Short cycle times, achieved by means of a high acceleration capacity, precise handling and continuous availability were seen as the keys to obtaining the necessary increased efficiency. The future two-shift operation and the planned doubling of the production rate also had to be taken into account in the design of the cell.

5) Body shop Mercedes-Benz A-Class (pdf)

DaimlerChrysler's Mercedes A-class body shop employs a variety of joining processes. For example, about 3,900 spot welds have to be made on 290 different sheet metal parts. DaimlerChrysler was looking to automate these processes through the use of robots; at the top of the priority list were short cycle times, which required high acceleration capability.


TQC: Automotive engine cleaning system

Staubli RX90 Robot: Loading of "blank pins to a rotary mould machine and removal of "finished" pins with moulded component to stripping table

Staubli RX90 EX Robot: Spraying on reflective paint into rear light cluster mouldings

Staubli milling machine with 1 robot: robotized high frequency milling for automotive part.

Kuka: Hemming a car sunroof