Automation on the fringes of possibility
Starting point / Task definition
As a world leader in the design and manufacture of plastic components and assemblies for the automotive industry, Plastic Omnium delivers integrated systems and solutions for the world’s leading car manufacturers.

The task definition for DAT was to develop an automation method for the production of glass fiber mats at working temperatures of up to 250 degrees Celsius. The solution had to be tailored to the specific demands of the highly automated production processes in glass fiber technology, while also being able to keep pace with the rapid changes in technology.
Implementation / Solution
Automation on the fringes of possibility
Automation on the fringes of possibility
The production process begins with a jointed-arm robot taking six glass fiber mats from a special device and depositing them onto a furnace carriage. This process is carried out with a special needle gripper, because when first picked up the mats consist of a pasty substance.

After heating, the components are picked up by the same robot and palletized in accordance with a programmed scheme. In the gripper the mats are linearly compressed, placed in the second furnace and heated once more.

After this the mats are taken by the robot and roughly pre-formed by being turned over (bubble falls down). The actual forming process then begins using a heated 3D pattern. The mats are pre-modeled, placed in the mold and pressed into their final shape. The finished component is then set down.
System components / Scope of supply
For this production installation DAT supplied all modules with the exception of the furnaces. All demands and requirements were taken into consideration individually in the overall system and process planning.

Both KUKA KR 125-3 jointed-arm robots are equipped with heat-resistant special grippers (material temperatures up to 250 degrees Celsius), which, for reasons of their functions, were fitted with up to 90 inputs and outputs and have an unloaded weight of about 100 kg.

In addition to the equally heat-resistant gripper interface module, DAT also supplied the 2D and 3D patterns for shaping the components in the gripper as well as the entire safety technology, the palletizing stations and the conveyors.
Results / Success
The automation method for the production of glass fiber mats was commended by the 7th Automotive Division Award and set new standards for automation solutions in the glass fiber industry. The production systems installed in the USA are constantly monitored at DAT headquarters via data modems and distance monitoring software.
Number of report
R 014
Industry
Automotive suppliers
Application
Handling, loading and unloading
Palletizing
Packaging and order picking
Other handling operations
Product
Robots
High payloads (100-240 kg)
Controller
KR C (Robot Controller)
Customer
Plastic Omnium, USA

URL:
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