Hongbao
Automotive collaborative robot
Recently, an automotive parts supplier implemented a manufacturing innovation using collaborative robots, primarily producing suspension, powertrain, and interior components for automotive companies. Automotive collaborative robots can be set up to inspect engine bracket sub-assembly lines in a repeatable manner based on factory needs, reducing the workload on manual labor.
Automating the inspection of engine bracket sub-assemblies is challenging, involving a crucial steering gear harness connector. The automated detection system also needs to keep pace with the line's high capacity while ensuring proper connection with the electrical connector within the harness. Initially, the automaker employed a fixed multi-camera system, but it could not position the cameras in tight locations, and the data collected by the fixed camera system was incomplete. The company also tried probe robots and manual inspection procedures; neither improved repeatability.
The new solution uses a UR10 collaborative robot, the largest of the collaborative robots, and Keyence's CV-X camera, part of the CA-HX200C LumiTrax vision system, to navigate the sub-assembly unit and provide repeatable inspection results. A ceiling-mounted UR10 cobot moves quickly between checkpoints, allowing the CV-X camera to capture an image of each connection before the collaborative arm retracts to its original position and waits for the next component to be inspected.
During sub-component inspection, each image is displayed immediately on a screen next to the robot, while a second screen with an engine bracket diagram displays green or red check marks as each checkpoint is completed, indicating pass/fail. The company's manufacturing execution system (MES) collects the pass/fail data and stores this information on the camera's memory card for two days.
Diesel and gasoline engine engine brackets have 11 and 9 checkpoints, respectively, and any engine product needs to be identified. Identifying different engine types and other key data requires the robot and camera system to communicate with the assembly line programmable logic controller (PLC) via industrial Ethernet. The system will run a first pass on all checkpoints; if one parameter fails, the system will reset. There is a 60-second cycle time per station on the assembly line; the inspection cycle time is approximately 48 seconds, with the UR10 cobot taking about 32 seconds. This setup allows time for reruns on failures without stopping the entire assembly line.
In addition to flexibility, collaborative robots offer excellent safety features. If the robot arm encounters an object or person in its path, it will automatically stop operation. This is critical because operators sometimes respond to inspection alerts from the inspection station.
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