State-of-the-art automation systems for BEV component lines
In the competitive world of automotive manufacturing, innovation and reliability are key to maintaining production efficiency and meeting industry demands. HG Automation needed to overcome supply chain challenges and deliver a state-of-the-art automation system for a Tier 1 customer's new battery electric vehicle (BEV) component line.
From small service provider to full-service integrator
Large-scale project on a tight timeline
Recently, HGA’s development and design engineers, automation assembly teams, programmers and installation technicians were all brought to bear when a Tier 1 customer needed a turnkey automation system for a new battery electric vehicle (BEV) component line.
HGA was given a condensed timeline in which to design, build, debug and install a five-zone automation system that incorporated part handling, stud spot welding and adhesive dispensing for a BEV rear quarter assembly. However, when the customer’s usual robot supplier was stymied by supply chain issues, HGA turned to KUKA for help.
“We had been doing small collaborations with KUKA for some time, but this was our first large, turnkey automation project that we deployed with them,” said HGA Senior Business Development Director Aaron Burke.
In addition to a challenging timeline from design to delivery, the project had to meet cost and space requirements. “Essentially, we had to provide a cost-effective, smart solution with the right number of robots and technologies all deployed into as small a package as possible for our customer,” Burke said. “Once we got the customer’s specs, we went through a number of iterations, designing and redesigning the process to get a system that could output the right volume of parts.”
The solution: 86 KR QUANTEC robots
The KR QUANTEC series consists of all-purpose, six-axis robots with payloads of 120-300 kg which allow the versatility to reliably handle a variety of production applications. The series is also very adaptable to cost-effective cell planning, which fit precisely into HGA’s requirements.
“We needed to meet space, volume and aggressive cycle times, along with other criteria, and KUKA robots allowed us to do that,” said Andrea Conover, HGA manager of Program Management, who served as the project manager. “KUKA robots also have great track records of uptime and limited maintenance on the line.”
Integration Support
Ease of Integration with KUKA.WorkVisual
The KUKA.WorkVisual engineering suite is a comprehensive tool for configuring, programming, and diagnosing KUKA robots. KUKA.WorkVisual integrates all steps of the engineering process into a single interface for a seamless workflow. The suite allows users to program and simulate robot motions, test sequences, and optimize performance before deploying robots on the production floor. KUKA.WorkVisuals’s intuitive design and extensive functionality significantly reduce setup times and improve overall operational efficiency.
“This was my first programming experience with KUKA,” Witt said. “The KUKA.WorkVisual along with the KR C5 robot controller helped tremendously in reducing the debug time on the system. I was able to write logic out beforehand and work out all the issues prior to commissioning. Other brands don’t have a program that is as comprehensive.”
A Successful Partnership
This project has been a great experience for us. KUKA and HGA have developed a solid relationship with one another, and we’ve even started leapfrogging into other areas as a partner in different solutions. That benefits both of our organizations.