Collaborative robot to help operators mount wheels on cars.
Wheels, especially those of SUVs, can weigh more than 40kg, making them difficult for a single operator to handle.
On the other hand, for safety reasons, robots can usually only be used in separate environments away from personnel.
We resolved these two issues by building a collaborative robot (able to move in the same area as operators) to autonomously load wheels from a transport box and bring them into position on the vehicle’s hub.
This robot can transport up to two wheels at a time and can work for 24 hours continuously thanks to a charging station incorporated into the work area.
A typical work cycle follows this sequence:
- With any obstructions out of the way and the car in position, the robot leaves its charging station.
- Using a laser-guided navigation system, the robot moves to the wheel loading area.
- It stops at the edge of the mounting line.
- It independently loads one front and one rear wheel and moves in front of the rear hub of the car.
- It lifts the wheel to hub height and slides it into position.
- The operator mounts the bolts and screws them in.
- Once the first wheel has been secured, again independently, the robot moves to the front hub and positions the wheel there.
- Once this second wheel has been secured, the robot moves to the other side of the car and repeats the wheel loading and mounting cycle.
- When finished, the robot returns to its charging base.
Space is tight on mounting lines and it’s not always possible to have manoeuvring areas for traditional movements.
To overcome this, we adopted a motorised base with Mecanum wheels. These wheels allow the base to be moved in all possible directions horizontally.
To reduce risk, we chose to have the robot work with the car wheels in a lowered position and to only raise them when close to the mounting position.
A Laser navigation system completes the trio of technological choices. It is extremely flexible and can be reprogrammed.
- Allows work in an unprotected environment where possible
- Automatic wheel loading system without the need for energy storage. Very useful to avoid fire or accident risk during storage
- PLC that can manage the entire work cycle.
- Laser navigation system
- Personnel savings with transparent wheel loading and handling time compared to other work steps at the same assembly station
- Safety systems adapted to the working area and transfer speed.
- Flexibility in need to reprogram operational steps (PLC + laser navigation)
- Automatic wheel lifting (no operator effort).
- Continuous functionality, thanks to the integrated charging station in the work area.
- Drawer for storing batteries allowing easy and quick replacement in case of failure.
