APPLICATIONS OF

ROBOTS IN THE
AUTOMOBILE INDUSTRY
So far, robots have been mainly used in the
automotive industries, including their supply
chains, accounting for more than 60% of total
robot sales. Typically prime targets for robot
automation in car manufacturing are welding,
assembly of body, motor and gear-box, and
painting and coating. Automotive industries, as
the key application driver in terms of cost,
technology and services robotics industry, are
subject to fierce global competition.
Origin of robot supplier in the automotive industry
 Advantages of Using ROBOTS

• Cost Effectiveness : A robot can work twenty-

four hours a day without a break, and continuously
perform the same mundane tasks over and over again
virtually non-stop.

• Job Efficiency : Barring any computer errors,

robots will almost always get the job done quicker and
more efficiently than a human possibly could.
• Safety : Robots are able to withstand exposure to
extreme heat, chemicals in the air, and general physical
contact with parts and structures.
• Accuracy : Robots are able to be programmed to
perform precise intricate duties at much faster speeds
than any human could be expected to.
• Physical Capacity : Robots are not limited like
humans when it comes to performing many assembly
jobs like painting, finishing, welding, riveting, and
installation. Robots also don't have restrictions with
moving heavy objects or issues of fatigue.
The application of Robotics is mainly in the final
step – execution of design process and assembly
operations
The assembly processes are done at the different level of automation
giving a possibility of comparing and choosing the best automation
strategy for the particular plant location. The final assembly consists
of the three main processes called Assembly Parts. Each Assembly
Part in turn can be divided into Assembly Operations or Stations.
•Assembly Part 1 consists of five Assembly Stations and includes
the following: roll forming of a tailgate and doors and a fitting of
the cockpit.
•Assembly Part 2 also consists of five Assembly Stations and
includes mainly a fitting of the power train and glasses.
•Assembly Part 3 includes seven Assembly Stations, which are
typically fitting of trim panels, a cross member, a bumper, a
complete front end, wheels and a battery.
AUTO ASSEMBLY PROCESS
Gripping
• Robotic arm,
controlled
by
computer,
used to
move
objects and
place things

Stamping
• Stamping
out and
cutting
parts from
sheet
metal
 Welding
• Spot Welding
• Arc Welding
--------------------------------------------
– Parts can be welded
either through the
movement of the
robot or by keeping
the robot relatively
stationary and
moving the part past
the robot.
– For unmatched
repeatability,
uniformity quality,
and speed.
 Body in White Operation
• The shell of the vehicle
passes through a brightly lit
white room where it is fully
wiped down by visual
inspectors using cloths
soaked in hi-light oil.
• Under the lights, this oil
allows inspectors to see any
defects in the sheet metal
body panels.
• Dings, dents, and any other
defects are repaired right
on the line by skilled body
repairmen.
 Spray Painting
• E- coat
– an electrostatically charged bath of undercoat paint
(called the E-coat) that covers every nook and
cranny of the body shell, both inside and out, with
primer. This coat acts as a substrate surface to which
the top coat of colored paint adheres.
• After the E-coat bath, the shell is again dried in a
booth as it proceeds on to the final paint operation.
• Once the shell has been fully covered with a base
coat of color paint and a clear top coat, the
conveyor transfers the bodies through baking ovens
where the paint is cured at temperatures exceeding
135 degrees Celsius.
Spray Painting Operation
Interior assembly
Assembly of all of the
instrumentation and
wiring systems, dash
panels, interior lights,
seats, door and trim
panels, headliners,
radios, speakers, all
glass except the
automobile windshield,
steering column and
wheel, body weather
strips, vinyl tops, brake
and gas pedals,
carpeting, and front
and rear bumper
fascias.
Windshields used to be Today, windshields are
installed by hand installed by robots
Body and chassis mate
The chassis assembly conveyor and the
body shell conveyor meet at this stage of
production. As the chassis passes the body
conveyor the shell is robotically lifted from
its conveyor fixtures and placed onto the car
frame. Assembly robots, some at ground
level and some in work pits beneath the
conveyor, bolt the car body to the frame.
Body and chassis mate
Final Assembly
• Tyres
• Batteries
• Gasoline
• Anti-freeze

Robot fuelling Trim line

• Final Inspection audit
• Checkpoint off the line
• Troubleshooting
• Price label
Kuka KR 500 Robot
• Axes: 6
• Payload: 500 kg
• H-Reach: 2836 mm
• Repeatability: ±0.15 mm
• Robot Mass: 2350 kg
• Structure: KR 500-2
• Mounting: Floor
• High payload and large
work envelope
• Extension of the
reference load center
distance
• Integrated energy supply
• Efficient use of floor
space
Fanuc S-430iW Robot
• Axes: 6
• Payload: 165 kg
• H-Reach: 2643 mm
• Repeatability: ±0.3 mm
• Robot Mass: 1300 kg
• Structure: Articulated
• Mounting: heavy-duty
floor mount
• Slim arm and wrist
makes parts accessible
and fast speeds reduce
cycle times
• Uses Fanuc Servo Drive
System, resulting in fast
point-to-point
positioning
 IRB 6620
New competitive robot for the automotive industry by ABB

• Economical and Compact

• Can also work bending
backwards and has a
large downward working
area (semi-shelf)
• Use of Electronic Position
Switches(EPS)
• Reach: 2.2 meters
• Payload:150 kilos
• Weight: 900 kilos.
• Absolutely the lightest
robot in its class IRB 6620 – The agile spot welder
Thank You