ROBOTICS APPLICATIONS IN CAR MANUFACTURING INDUSTRY

              ROBOTICS APPLICATIONS IN CAR MANUFACTURING INDUSTRY

           

WHAT IS A ROBOT ? 

If you compare a conventional robot manipulator with a crane attached to, say, a utility or towing vehicle, you will notice that the robot manipulator is very similar to the crane. Both possess a number of links attached serially to each other with joints, where each joint can be moved by some type of actuator. A ‘robot’ is a machine especially one programmable by a computer capable of carrying out a complex series of actions automatically.

WHY DO WE NEED A ROBOT?

You might wonder whether you need a robot when you get bored by doing the work over again and again. The truth to be told, nothing will happen without machines. Most robots today are used to do various repetitive (boring and dull) tasks or actions which are dangerous and difficult for human beings to perform. 

They are used in various industries. They are capable of performing many different tasks and operations, are accurate, and do not require common safety and comfort elements humans need. 

So, we need robots for:

1. Improved Product Quality: 

             If you are looking for a good and better quality of your product in the industrial sector, then you should use robotics in your industry. The inherent accuracy and repeatability of robots means you can achieve a continuously high quality finish for every product produced.  

2. Improved Health and Safety:

             By using robots, you can decrease the accidents caused by contact with machine tools or other potentially hazardous production machinery or processes. They can also help to eliminate ailments associated with repetitive or intensive processes, such as repetitive strain injuries.  

3. Save Space: 

             Robots can be mounted in multiple configurations to help you save highly valuable space in various manufacturing areas. They can also be programmed to work in confined spaces so you do not lose valuable floor space.

4. Reduced Operating Costs: 

           Robots enable you to reduce direct and overload costs, making a dramatic difference to your competitiveness. For example, with no requirement for minimum lighting bills.  

What is ROBOTICS ? 

Robotics is the art knowledge base, and the know-how of designing, applying, and using robots in human endeavors. Robotic systems consist of not just robots, but also other devices and systems used together with the robots. Robots may be used in manufacturing environments, in underwater and space exploration, for aiding the disabled, or even for fun. The goal of robotics is to design intelligent machines that can help and assist humans in their day to day lives and keep everyone safe.

ARCHITECTURE OF ROBOTICS : 

Components included in the architecture of Robotics are:

1.  Actuators :

  Actuators are the muscles of robots, the part which converts stored energy into movement. From far time the most popular actuators are electric actuators that rotate a wheel or gear. In industries and many factories linear actuators are used to control the robots. Actuators are under the control of the controller. 

2.  Sensors :

            When you wake up in the morning, even without opening your eyes, or when it is completely dark, you still know where your arms and legs are. This is because feedback sensors in your central nervous system embedded in muscle tendons send information to the brain.The brain uses this information to determine the length of your muscles and, consequently, the state of your arms, legs, and so on. The same is true for robots, where sensors integrated into the robot send information about each joint or link to the controller that determines the configuration of the robot.   Sensors are used to collect information about the internal state of the robot or to communicate with the outside environment. 

3.  Controllers : 

             The controller is rather similar to your cerebellum; although it does not have the power of the brain, it still controls your motions. The controller receives its data from the computer (the brain of the system), controls the motions of the actuators, and coordinates the motions with the sensory feedback information. The common issued by the controller activates the motion control motion mechanism, consisting of various controller, actuators and amplifier. 

4. Processor: 

            Processor is the brain of the robot It calculates the motions of the robot’s joints, determines how much and how fast each joint must move to achieve the desired location and speeds, and oversees the coordinated actions of the controller and the sensors. 

Types of Robots : 

1. Legged Robot:  

          

              Legged robots are the type of mobile robots which use articulated limbs, such as leg mechanisms to provide locomotion. They are more versatile than wheeled robots and can traverse many different terrains, though these advantages require increased complexity and power consumption. 

2. Autonomous Underwater Vehicle: 

       

An autonomous underwater vehicle (AUV) is a robot that travels underwater without requiring input from an operator. AUVs constitute part of larger group of undersea system known as unmanned underwater vehicle.

HOW ROBOTICS IS USEFUL IN CAR MANUFACTURING INDUSTRIES?

Robots are helping different automotive manufacturers in different ways to improve their automation processes. There are thousands of parts in every car and truck, and it takes myriad manufacturing processes to make them. Advances in automotive robotics technology, such as vision systems and force sensing, mean more of these than ever are suitable for robotic automation. 

Here are some best suited application areas: 

1. Spot and Arc Welding: 

     

            Spot welding is a resistance welding process that is used primarily for welding two or more metal sheets together by applying pressure and heat to the weld area. Large industrial robots with long arms and higher payload capabilities handle spot welding on heavy panels. Smaller robots weld lighter parts such as mounts and brackets. Robotic tungsten inert gas (TIG) and metal inert gas (MIG) welders can position the torch in the exact same orientation on every cycle. Preserving high welding standards in every fabrication is doable due to the repeatable arc and speed gap.

          This is one of the most common applications of robots in automotive industry. Due to their consistent movement, robotic welds are very uniform and accurate. Welding robots are very large and powerful. Robotic welders and handlers must collaborate to keep the assembly line moving. Robot handlers need to place panels at the precise location so the welding robot can perform all the programmed welds.

2. Painting, Coating and Sealing : 

   

     Painting is another very common application of robotic, especially in the automotive industry. Able to follow a programmed path consistently, robots are widely used for painting in car assembly plants, but are also good for spraying coatings such as sealants, primers and adhesives. And also they can lay uniform bead of sealant prior to assembly. Labor shortages are also making it harder to find skilled, professional painters.

3. Robotic Vision :

     

A light industrial robotic arm with “eyes” can do more precise work because it can see what it is doing. The robot wrist carries the laser and camera   array that gives the machine instant feedback. Robots can now perform proper offsetting when installing a part, because they know where it goes. Installation of door panels, windshields, and fenders are more accurate with robotic vision than regular robot arms.

4. Material Removal :

          Robots can follow a complex path repeatedly in multiple times without failing making it the perfect tool for cutting and light trimming. Examples include cutting fabrics such as headliners, trimming flash from plastic moldings polishing molds and cutting fabric.

5. Robotic Hand Gesture : 

        

As we know the automotive industries are using large number of industrial robots in the production line, human workers contribute to the final completion of cars. The most of manufacturing operations are done by industrial robotic hand. This technology gives a supplementary 1000 pounds of force to the workers.

6. Part transfer and Machine tending:  

Transferring metal stamps, loading and unloading CNC machines, and pouring molten metal in a foundry is dangerous for human workers. This type of work is perfect for large industrial robots. Machine tending and loading/unloading tasks are also being done by smaller robots for small manufacturing operations.

7.  Assembly Tasks:

      Assembly tasks usually involve many tasks. Tasks such as screw driving, windshield installation and wheel mounting are all candidates for robotic arms in car manufacturing plants. In many automotive parts plants, robots are assembling smaller component assemblies such as pumps and motors. Many of the fitting and assembling tasks are complicated and may require pushing, turning, bending, wiggling, pressing, snapping the tabs to connect the parts and other operations. Cars were created by a combination of machine and human power. Car parts, such as engines and rims, were manufactured in large numbers by machines. Each car was pushed down a conveyor belt and assembled piece by piece, until it was ready to be shipped off to its new. 

    CAR MANUFACTURERS WHICH USES ROBOTS: 

1. Ford : 

Collaborative robots work together with Ford engineers to apply finishing to Fiesta vehicles on the production line. The six robots complete a choreographed sequence to send the entire body surface in just 35 seconds. 

2. BMW : 

BMW Munich assembles 1,000 cars a day, with the help of robots. Unit numbers are much lower than in Munich, but the local factory also uses robotics.  

3. GM : 

     GM is also taking advantage of technological advances with its more standard industrial robots pursuing zero-downtime technology with strategic partner Fanuc.