Comau has built an advanced, automated welding solution for Beijing Foton Daimler Automotive (BFDA), a joint venture between Daimler Trucks and Chinese truck manufacturer Foton Motor. In sodoing, Comau is helping support BFDA’s first localised heavy-duty truck for the Chinese market, the ‘Actros’, which is based on the Mercedes-Benz global platform and uses Daimler’s most advanced truck technology.

Featuring 100% process automation, the Comau-designed production line is completely flexible in order to handle complex model management and variable output management. With a target annual production capacity of 50,000 units, Comau’s welding solution will meet both the customer’s current and future production requirements.

Under the scope of the project, Comau’s engineering team was tasked with mastering the Daimler Integra 6 standard to create an automated, flexible, intelligent and digital welding line for both the door area and the framework of the instrument panel.

Built to ensure cycle efficiency and streamline workflows, the solution features proprietary Comau products, such as RH-Clean, an automatic cleaning roller device that can be used with different types of rollers and pre-hemming tools, and a quality-control vision system that uses QUISS camera detection and is equipped with a kick-in/kick-off process to ensure the quality of the parts after gluing. Finally, the project also leverages virtual commissioning technology to help test and optimise the new production line while shortening the actual commissioning time, reducing labour hours and reducing potential post-site commissioning risks.Mass production will start this quarter.

“Throughout this successful collaboration, the Comau team played an important role in improving the competitiveness of our products,” says William Sparenberg, head of Mercedes Benz Truck Factory.“We are particularly impressed with their expertise in various aspects such as design, reliability and cost.”
For further information www.comau.com

Custom pump manufacturer Scherzinger Pumpen in Furtwangen, Germany, is aiming to increase the level of automation in production so that employees tied up with simple tasks can work in more demanding activities. Another motivation for automation is to increase the efficiency of existing machinery.

The first automation project was the loading and unloading of a Kellenberger cylindrical grinding machine. Two main features were included in the requirements profile. First, it had to be possible to continue loading small batches manually and have full accessibility through the operator door for set-up. At the same time, space is limited, so the new automation process had to fit into the area occupied previously by the machine operator.

Scherzinger Pumpen turned to nearby EGS Automation, which has been offering experience in robot automation since 1999 and has already installed more than 2000 robots. Further discussions revealed that one of the EGS standard automation solutions from its Sumo series was suitable for the requirements. A standard solution saves costs since the engineering effort is significantly lower. Furthermore, a standard product line is tried and tested and has found use in various applications.

The Sumo Multiplex, a 12-fold palletising system based on the paternoster principle turned out to be the perfect solution for Scherzinger. A Motoman GP7 robot from Yaskawaperforms component handling. This six-axis jointed-arm robot has a range of approximately 1 m with a payload of 7 kg. The fast travel speed and high accuracy ensure rapid, reliable and accurate part changes in the machine.

Patrick Wehrle, machine operator at Scherzinger Pumpen, is enthusiastic about the automation system: “The robot relieves me of monotonous tasks. I had no robot experience before, but now,after programming training at EGS, I create new programs myself.”
For further information www.egsautomatisierung.de

Kuka’s new ‘Edition’ robots will help customers automate welding tasks efficiently in price-sensitive markets. Initially, the KR CyberTech nano ARC will initially be available in two Edition variants, with other Kuka robots to follow.

No one would drive a Formula Onecar on a highway, so why use a highly specialised process robot for very simple applications? The new hollow-wrist KR CyberTechnano ARC HW Edition robot is for simple arc welding. Edition robots draw on Kuka’s current technology portfolio, including the newly updated KR CyberTech nano series, the latest-generation KR C5 controller and appropriate welding software, such as Kuka.ArcTech Basic.

“Instead of downsizing, we are opting for ‘right-sizing,’” explains Markus Hollfelder-Asam, portfolio manager at Kuka. “The Edition robot variant offers simplified, focused, reliable technology that remains a genuine Kuka original.”

For customers in highly dynamic and price-sensitive markets, the adapted design of the Edition robot significantly lowers procurement costs, reports Kuka.

The KR CyberTech nano ARC HW Edition robot is for payloads up to 6 kg and is suitable for installation on the floor or ceiling. To match varying requirements in the entry-level segment, Kuka offers two versions of the Edition robotwith reach up to 1440 mm or 2010 mm. The standard version uses a 50 mm hollow wrist with bearings on one side, whereas the Edition robot features a hollow wrist with bearings on both sides, a diameter of 46 mm and 0.04 mm repeatability.

“This is exactly right for entry-level applications in the field of arc welding,” Hollfelder-Asam confirms. “We were determined to deliver typical high Kuka quality. This means the hollow wrist supports optimal positioning for the welding process and avoids additional disruptive contours.”
For further information www.kuka.com

As a specialist in material handling and supply chain solutions, the Kion Group relies on Cloos automation solutions for welding industrial trucks. In total, the group uses more than 70 Cloos robot systems at eight manufacturing sites worldwide.

“In the years of collaboration with Cloos, we were able to develop new technology standards that have created added value for both sides,” explains Jürgen Grünewald, senior project manager – welding andautomation production technologies at the Kion Group.

For example, Cloos and Kion have developed a chained robot system for the automated welding of masts at the Stribro site.

With more than 40,000 employees in over 100 countries, Kion’s solutions improve the flow of materials and information in production plants, warehouses and distribution centres. More than 1.6 million forklift trucks and warehouse trucks and around 8000 installed systems are in use worldwide – at customers of various sizes in numerous industries.

The Stribro site in the Czech Republic has grown very strongly since opening. Around 70 of the approximately 400 employees work in the welding area. Due to the general shortage of skilled workers and many industrial companies in the region, it is not easy to find qualified employees. Kion wants to counter this issue with a high level of automation. The company currently uses seven robot welding systems at Stribro, with another in the assembly process.

“We chose Cloos because the company is the best provider on the market when it comes to combining welding processes and robot systems,” Grünewald emphasises. “This is a big advantage for Kion because welding is a key manufacturing process for us.”
For further information www.cloos.co.uk