Breakthrough and Solution of Stäubli Industrial Robots in Automotive Flexible Production Lines

Stäubli has a century of experience in precision mechanical design and manufacturing and high-speed motion control. The automotive industry is one of the most used industries for Stäubli industrial robots. In response to the needs of the automotive industry, Stäubli promoted the RX160L flip-chip gantry structure robot flexible cutting system solution. As shown in the figure, the system made a major breakthrough from the following aspects:

Breakthrough 1: Large size robot wide format

Using RX160L robot, 2.05m ball working area, the cutting table width can reach 3m, the general auto parts size is in the RX160L flip-chip robot working area, and some large workpieces can also be realized through the mobile platform. The width of the table exceeds that of the expensive five-axis machine. Other general robots are non-spherical working areas, so the actual cutting will encounter dead angles, forcing the cutting to be interrupted and re-arcing, which is unacceptable to customers in the automotive industry.

Breakthrough 2: Light weight and good rigidity

Stäubli uses a monolithic cast tubular structure to maintain rigidity; the material uses aerospace cast aluminum with less deformation but light weight. The weight of the RX160L robot arm is only 250kg, and the robot with the same arm in Europe has to reach more than 400kg or more than 600kg, which is very unsuitable for the flexible laser cutting of robots. This is also demonstrated in actual projects.

Breakthrough 3: Differences in mechanical precision of robots

In addition to the difference in rigidity of the mechanical precision of the robot, the most important difference lies in the error of the mechanical transmission, and the error of the mechanical transmission is mainly reflected in the reducer. The deceleration systems of general robots are very large, and they all adopt the structure of ordinary reducer, and the gear clearance is large, which can not meet the needs of robot flexible laser cutting in the automotive industry. The unique patented deceleration system JCS used by Stäubli has successfully applied the company's more than 100 years of experience in precision machinery to robots, which is efficient and precise. That's why Stäublier Bill is highly recognized by customers for small hole cutting.

The flexible solution based on the RX160L flip-chip is adaptable to different products and production efficiencies.

The basic solution is a fixed work surface type, which is characterized by a small footprint, partitioning the product by robot safety signals, and the user can fix the fixtures of multiple workpieces at the same time. As long as the integrated safety system can guarantee that the robot can be different Work station switching, cutting and loading are not lost, this is also the most economical solution. This is favored by customers in the automotive spare parts market and in many smaller batches.

Other flexible solutions are based on the openness of the RX160L robot, which evolves through different forms of extension axes and displacement mechanisms. For example, a single platform large-format, two-way dual mobile platform, one-way dual mobile platform, mobile platform to expand a single or rotary position machine for simultaneous synchronous cutting. The variety of auto parts is complicated and the process is complicated. The multi-robot platform group can be well adapted to the needs of the automotive industry. At the same time, the loading, unloading, transporting and warehousing of the workpiece can be performed by robots, making full use of the flexibility of the robot, so that the robot can flexibly cut. The system has evolved into a multi-robot collaborative centralized control platform.

Five-axis machine tool technology successfully transplanted on the robot

Off-line programming technology and automatic tooling are one of the key technologies that have been promoted in the machine tool industry. The development and successful application of these technologies in the field of robotics enable robotic flexible laser cutting solutions to seamlessly link with automotive industry application customers.

The traditional robot programming method is online teaching programming. The teaching programming itself is time-consuming and laborious, especially for automobile covers or Pipe Fittings. All the cutting needs are complicated space curves. The teaching cannot meet the design requirements, even if the teaching cost is reduced. Can't accept it. The application of robotic laser cutting off-line programming software greatly shortens the programming time and does not affect the online processing. as the picture shows.

High-efficiency machining is an important factor in the promotion of five-axis machine tools in the automotive industry. At present, the most important reason why most auto manufacturers do not accept robots is the comparison between the processing efficiency of a single robot and the efficiency of five-axis laser cutting. And we believe that efficiency is determined by the advantages and disadvantages of integration solutions and integration experience. Many integrators choose ordinary robots that are not suitable for laser cutting, which are inefficient and ineffective, affecting the perception of users in the automotive industry and negating the robot solution. Our point of view is that the excellent integrators will use high-precision robots to integrate into the precise system structure, and evolve from basic models to different robotic flexible cutting schemes according to different user products. It can be single, dual or multi-machine. The number of platforms is combined.

The level of integration capability of the integrator determines the final cutting effect and efficiency. Germany JENOPTIK is a laser application integrator from Stäubli, using Stäubli's custom-developed TX90 laser cutting robot, custom light cutting head and unique BIM (Beam-In-Motion) technology. The device has a small hole positioning accuracy of ± 50 mm and a linear speed of more than 12 m/min. If the product yield is high, JENOPTIK can offer two-machine or multi-robot solutions. The picture shows that JENOPTIK's custom robots are undergoing thermoformed high-strength steel cutting, which has been used successfully on the Volkswagen POLO models.

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