Embracing cobots on the assembly line

The UR cobots are the centre of the production line of DDUs, key components in the regeneration of diesel engine particulate filters. The assembly line has a 30 second cycle time and deploys a UR5e cobot (5 kg loading capacity and 1.5 m operating diameter) installed on a ceiling-mounted 7th horizontal axis and three other UR5e cobots on a line cycle in an adjacent station.

The cobot installed on the 7th axis loads the components to be assembled on the station and removes the finished product at completion of the assembly cycle. Integration with the linear axis gives the cobot an extra degree of freedom for enhanced flexibility.

The second UR5e cobot, located in the neighboring cell, applies a holding device on the component. In this case, use of the cobot provides flexibility and ensures application safety, allowing the cell to remain open so that the operators can interact with the production process and carry out any necessary maintenance. The third and fourth cobots apply lubricant to the finished product and handle a series of process control cameras, using artificial intelligence protocols to check that all the components are present.

Thanks to a UR3 cobot, Vitesco Technologies Italy has freed an operator from the physically demanding and repetitive task of palletizing armatures on a metal tray. On this application, a belt conveys the armatures to a selector, which positions them on the pick-up spot by means of an overhead electric axis moving in parallel with the direction of the conveyor and a pneumatic axis, which moves perpendicularly to the conveyor. When the armatures are in position, the UR3 cobot picks up two at a time with a customized double gripper and palletizes them on a metal tray. The palletizing pattern was developed with Polyscope wizard. After lowering the speed and acceleration of the application to reduce wear on the joints and ensure greater precision, the Vitesco decided to use a double gripper able to pick-and-place two armatures in the same cycle to optimize productivity. A crucial area on which the company has focused is versatility: with a series of simple adjustments, such as the gripper modification and the selection system, the company is able to manage and palletize a variety of components, for a diversified application.

Thanks to the Universal Robots cobots installed on its lines, Vitesco Technologies Italy has significantly improved the ergonomics of its internal processes. Specifically, the automation of a series of complex assembly tasks previously performed manually has allowed the company to move its workers to jobs with greater added value, optimizing throughput.

Second, the company has benefited from the flexibility and collaborative nature of the UR cobots: the machines operate largely in open workstations where operators can intervene if necessary.

Finally, significant reductions in cycle time have been achieved on a range of processes, for greater productivity.