Embracing cobots on the assembly line

On the fuel rail production line (one of the diesel engine components that present the highest degree of assembly complexity), ten UR10 cobots (with a 10 kg payload and a reach of 1300mm) positioned in pairs on five identical assembly lines play a vital role. Their job is to automate component loading and unloading, previously performed manually. The cobots were installed on the line without requiring any substantial changes in the layout and production structure: a result made possible by the collaborative nature of the cobots that have built-in safety systems enabling their use without fencing (based on a risk assessment).

The introduction of the cobots has cut cycle time by 11% and freed the line operators from more than 70% of the most repetitive and ergonomically unfriendly operations.

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.

To lower polluting emissions, modern diesel engines are fitted with Selective Catalyst Reduction (SCR) catalyzers, that cut nitric oxide emissions by using a reducing agent injected through a Reduction Dosing Unit (RDU). Five UR5 models have been installed on the RDU assembly line for the application of a protective rubber component on the RDU tubes. The product design has a wide range of tolerances to accommodate the assembly of a variety of subcomponents, which is why high insertion flexibility is needed during assembly.

To guarantee handling of caps of various dimensions, the Robotiq cobot gripper has adaptive capabilities and its own strength control to ensure the right reaction during forced insertion. The application has eliminated no-value manual operations and improved line efficiency.

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.