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INSIGHT Detroit, MI, USA Schuler Hydroforming and Schuler Automation, Detroit, MI, have joined forces to produce a system using robots to link integrated hydroforming production systems for a Canadian automobile industry supplier. The hydroforming automation equipment is used to produce small-truck bodywork frames for GM. Schuler Automation was responsible for all automation components, and for ensuring smooth material flow of the pipes from the bending machine to the laser cell at the end of the production belt. To ensure speedy, trouble-free start-up, all robotic movements were precisely tested and coordinated in advance, during a realistic simulation exercise. Over a three-week period, Schuler Automation used robots of the type used by its customer to prepare a team of experts in its Gemmingen (Germany) plant for the programming and start-up of each automation stage. The different pipe section sizes of the hydroformed parts presented a particular challenge. The robots' grippers had to be precisely adjusted and set. Because of the special applications, each robot arm requires different gripper jaws, which were individually tested and fitted with a special plastic. Because of its physical properties, this plastic has an extremely high coefficient of friction, which keeps components firmly secured in the robot arms. Although it was being used the first time, the experience with this plastic has been positive. The design of the automation components for the hydroforming system was based on process steps from pipe to finished hydroformed component, as well as on the changing dimensions of the pipes. At the beginning of the production line is a bending cell and a component conveyor. Next is a preforming press, fitted with double tooling, where the pre-bent pipe is laid in the preforming die. Concurrently, the preformed component is set in the flattening die. A second die removes the flattened component and lays it in the hydroforming press. After the actual hydroforming process, the third step in the process removes the completely formed components, laying them on the second component conveyor. The experience gained in starting up the system has shown that simulating complex automation procedures in advance is beneficial for overall project planning. It also offers the option of testing and optimizing innovative components before their use in serial production. The pneumatic gripper arm's jaws are made of special plastic with a high coefficient of friction for a low-pressure, non-slip grip. The robot's movements are simulated at Schuler's Gemmingen (Germany) plant using original components.
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Source: Welding Design & Fabrication, Including Welding Engineer
Copyright Penton Media, Inc. Jul 2002
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