A Look into How Articulated Industrial Robots Are Helping the Automotive Manufacturing

Highlights

• Introduction
• Precision, consistency, increased efficiency, and cost savings
• Safety improvements and adaptability

 

Articulated industrial robots are robotic arms with joints, that copy the flexibility and range of motion of a human arm. They typically have multiple rotary joints that allow them to move and position with precision in three-dimensional space. These robots are widely used in manufacturing for tasks such as welding, assembly, and material handling due to their versatility and efficiency.

These sophisticated machines, with their multi-axis arms and advanced capabilities, have changed automotive production processes across the globe. They perform repetitive tasks with speed and accuracy, reducing production times and costs. Moreover, they handle hazardous materials and tasks, improving worker safety, and their flexibility allows for rapid reprogramming and adaptation to new production demands. This promptness ensures automotive manufacturers stay competitive in a fast-evolving global market.

Ensuring a balanced design among the major aspects of manufacturing

Articulated industrial robots perform tasks such as welding, painting, and assembly with high accuracy, ensuring components fit perfectly and meet stringent quality standards. This precision minimizes rework and rejections, theeby reducing costs and improving overall efficiency. Moreover, consistent performance across tasks ensures uniformity in production output. Whether assembling parts or applying coatings, robots execute operations identically every time, eliminating variations that can occur with human workers. This develops product quality and reliability, which are crucial in automotive manufacturing where safety and performance are the focus. Additionally, robots work tirelessly without fatigue or distraction, maintaining optimal productivity levels throughout their operational hours. This capability significantly boosts output rates and enables manufacturers to meet demanding production schedules consistently.

Precision in robot movements also allows for tighter tolerances and finer detailing, which is important for intricate assembly processes in modern vehicles. They ensure the exact positioning and application required, contributing to the durability and functionality of automotive components. Robots also perform tasks swiftly and perfectly, reducing cycle times and improving productivity. They minimize downtime and resource wastage, thereby lowering production costs. Improved efficiency in robotic operations organizes manufacturing operations allowing automotive companies to meet growing demands in the competitive scenario. Yaskawa Electric Corporation partnered with Toyota in 2018 where Yaskawa's industrial robots were implemented to automate various assembly tasks, including precision welding and part handling. This collaboration focused on improving process efficiency by reducing cycle times and enhancing product quality through consistent robotic operations. The integration of Yaskawa robots also contributed to cost savings by lowering labor costs and minimizing defects, thereby optimizing Toyota's manufacturing processes.

While initial investments in robotics are significant, the long-term operational savings justify the investment. This includes reduced labor costs, decreased scrap rates, and improved resource utilization. For instance, in welding operations, industrial articulated robots ensure detailed and consistent welding, minimizing material waste and rework costs. They also operate continuously without breaks, reducing labor costs associated with human workers. Furthermore, restructuring production processes and optimizing resource utilization, they keep operational expenses in check. In 2015, KUKA collaborated with Ford and integrated KUKA's advanced robotic systems into Ford's production lines to improve welding and assembly processes. These robots ensured precise component placement and consistent weld quality, leading to reduced rework and scrap. It targeted to increase efficiency by optimizing cycle times and lowering operational costs through improved productivity and minimized material waste.

Safety improvements and adaptability help in gaining competitive edge

Robots handle hazardous tasks such as welding and handling toxic materials, minimizing workers’ exposure to safety risks, and improving overall workplace safety. Advanced sensors and collision avoidance systems ensure safe interaction with human operators, reducing workplace accidents. Moreover, these robots can be easily reprogrammed and adapted for different tasks and production scenarios, improving agility and responsiveness in a dynamic manufacturing environment. This adaptability allows automotive manufacturers to quickly adjust to changing production demands. It also helps to introduce new models or configurations without significant retooling or downtime significantly contributing to the growth of the articulated industrial robots industry.

FANUC, a leading robotics manufacturer, collaborated with BMW in 2016 to integrate advanced vision systems and collaborative robot technologies to safeguard workers by allowing robots to operate near humans. It aimed to increase flexibility on BMW's assembly lines, enabling quicker adjustments and setup changes for different vehicle models. In 2020, ABB also partnered with Volkswagen to implement collaborative robots called cobots, in their manufacturing facilities. These cobots are equipped with sensors and software that enable them to work alongside human workers safely. The collaboration focused on improving adaptability by using robots that can quickly be reprogrammed for different assembly tasks, bettering Volkswagen's production flexibility while maintaining high safety standards in their automotive manufacturing operations.

Endnote

Articulated industrial robots have reconceived automotive manufacturing by improving efficiency, precision, and flexibility across production processes. Through increased efficiency in assembly, painting, material handling, and quality inspection, these advanced machines have become indispensable in modern automotive plants. Robots are expected to increasingly be connected to the Internet of Things, enabling real-time monitoring, predictive maintenance, and remote management in the years ahead. Moreover, progress in cobot technology is expected to expand their role in automotive assembly lines encouraging closer human-robot collaboration and further improving workplace safety and efficiency.

For more insightful information and industrial updates on articulated industrial robots and their increasing significance in the automotive industry, reach out to our experts.     

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