German company introduces new automated car-assembly technologies
Wednesday, September 14, 2011 at 03:08PM 
KUKA Systems' new SAM robotic cell applies an acrylate sound-proofing compound that replaces heavier bitumen or butyl mats that have to be custom-cut and hand-positioned, one of two new technologies from KUKA to improve the efficiency and environmental performance of carmakers.
KUKA Systems, headquartered in Augsburg, Germany, has unveiled two automated application technologies that it says will benefit automobile manufacturers as well as the environment. The two technologies were developed in-house with the encouragement of a European-based, global automobile manufacturer that has signed on as launch customer for both.
The first is referred to as SAM: Injectable acoustic insulating compound. SAM technology allows automakers to use an acrylate acoustic insulating compound for vehicle sound-proofing, applied by a robotic cell, in place of the traditional bitumen or butyl mats that have to be custom-cut and hand-positioned. The robot cell consists of three industrial robots that apply the substance to doors, tailgates and other car parts on the assembly line. Acrylate is more environmentally friendly than bitumen mats, and also lighter. The automated application system is flexible enough to adjust to any vehicle type or model. It's also highly reliable, having achieved over 98 per cent operational availability in a three-shift-a-day environment.
The second new technology is HRK: enhanced application of corrosion protection. The HRK process consists of point-by-point and sequential wax application for corrosion protection. Using a dual, automated sweep makes it possible to cover a larger area in less time. The in-line nozzle cleaning performed during the process is an industry first, and is both resource conserving and environmentally friendly, employing a water bath and automated disposal of the cleaning fluid.
Advanced bonding processes are indispensable for composite materials construction of the future, such as joining plastic to steel or steel to aluminum that cannot be welded together. The advantages include a uniform distribution of tension and application of force over the entire bonding surface. The adhesive and sealant has the additional properties of serving as an electrical insulator and providing protection against corrosion. "There are many good reasons for the automated application of adhesives and sealants," says Gerhard Hartmann, Product Group Manager for Technology Solutions at KUKA Systems. "The quality with which the adhesive and sealant bead is applied remains constant. Different seam geometries can be generated quickly and easily, and the application is carried out with high speed and precision."
KUKA Systems was one of the first production line builders to implement bonding and sealing technology for the key stages of automobile manufacturing: body-in-white production, paintwork and final assembly. The company developed its first bonding solutions 26 years ago. One of the first was glass bonding in the final assembly of vehicles.
Reader Comments (1)
We need to stop the use of machines so much in doing jobs If the machines go down the computers go down now adays the people don't know how to do a job by hand I see it all the time now plus we have lost millions of jobs when machines keep replaceing the human who is going to have the money to buy anything and we are letting big CEOS get rich as we lose everything even are health with machines doing the work when are the people going to WAKE UP BEFORE IT'S TOO LATE