AMS | India Conference | Pune

 Date : 09. – 11. December 2013

 Automated & Flexible Arc Welding Line for Automotive Chassis, RTB & FCM

 Amar Patil
Sales, Engineering & Projects
 KUKA Systems India Pvt. Ltd
 KUKA Group - Structure

KUKA AG

KUKA Robotics KUKA Laboratories KUKA Systems

 Customer Service  Medical applications
 Controller  Service robotic Planning | Body Technology
 Robots  Productions-
Engineering Structure Solutions
 Software Assistant
 Application modules

Assembly & Operating |

Tools & Dies
Test Production

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KUKA Project

Automated & Flexible Arc Welding

line for Automotive Chassis

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Chassis Welding Project Overview
• Design, Manufacturing & Supply of Entire
Line for Cycle time of 124 seconds with :

• Integration of Robots : 39 Nos.

• Welding Fixtures.
• Robotic Grippers.
• Variants considered : 15 Nos.
• Automated Material Handling Systems.
• Mezzanine Structures
• Part Identification & Marking System.
• Air, Water & Gas supply Systems
• Complete Electrical & Control System.
• Cycle time & Quality Prove-out

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Overall Chassis Welding Layout & Material Flow

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Chassis Front Mod Group Cell
• Loose parts loaded by operator.
• Robotic gripper picks front mod loose parts
and load on tack & geo fixture

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Chassis Front Mod Group Cell
• Dual component robotic gripper & Re-weld
stations.
• KUKA standard positioner.

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Chassis Rear Mod Group Cell
• Loose parts loaded by operator.
• Robotic gripper picks front mod loose parts
and load on tack & geo fixture

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Chassis Rear Mod Group Cell
• Dual component robotic gripper & Re-weld
stations.
• KUKA standard positioner.

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Chassis Mainline

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Mainline

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 RTB & FCM Project layout

Front Cross Member

Rear Twist Beam

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 FCM Robotic Weld line

• Complete robotic weld line.

• Synchronized robots working as mirror welding on same part.
• Utilization of KUKA standard positioners

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 RTB Robotic Weld line

• Complete robotic weld line.

• Synchronized robots working as mirror welding on same part.
• Utilization of KUKA standard positioners

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 Special Fixtures designed & supplied

• Bush pressing fixture for LCA

• Toe & Camber checking fixture for rear axle
• PLC operated and computerized reports generation for toe & camber angles.
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 Thank you !!!

KUKA Systems India

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