How to Benefit From Lessons From Automated Automotive Assembly Lines

Robotic Assembly Systems Offer Incredible Manufacturing Automation Solutions for the Automotive Industry

Robotic assembly automation is steadily becoming the single most dominant force in manufacturing. The speed and quality demanded by industrial production are not something human workers can do alone. To this end, many assembly equipment manufacturers now offer machines known as cobots. Cobots allow semi-automatic assembly, which keeps a person in the driver’s seat while a machine performs physically difficult or highly precise tasks.

However, more radical change is still on the horizon. The automotive industry has always been at the forefront of automation in manufacturing. Countries with strong automotive sectors are moving towards fully automated automotive assembly lines at staggering rates. In South Korea, there are over 850 robots per 10,000 manufacturing employees, and there is one robot for every five employees in the automotive industry itself.

Trends like these make ideas like Tesla’s ‘lights out’ factory look increasingly feasible. But what is it about the vehicle industry that makes it so ripe for automated automotive assembly lines and systems, and how do these systems work?

Where Industrial Assembly Meets Powerful Automation

A vehicle can contain as many as 30,000 individual parts. Obviously, these are not all assembled in one place, but that figure gives a sense of the sheer scale of the work required. Between power trains, transmissions, and structural components, carmakers have numerous automotive component manufacturing needs. As a result, they require a massive range of processes and connection methods to bring a new car to completion.

Luckily, automated automotive assembly lines are particularly effective at making vehicles. Pieces move consistently and regularly through the plant, reducing the need for human interaction. Additionally, robots are now capable of diverse high-level assembly tasks, complete with in-line and on-machine metrology to make process control seamless.

Torque and Fastening Systems

Proper torque is vital when creating a safe vehicle, and car manufacturers have dozens of different demands, both in size and precision. From high-torque, wide-tolerance lug nuts to the precision of attaching an air compressor to an engine block, humans have historically installed torque systems due to the delicacy required and the high cost of failure. But new advancements are allowing assembly equipment manufacturers to implement carefully calibrated torque systems.

This new capacity for process control comes in the form of both in-line and on-machine metrology. On top of offering both blow-fed and track-fed torque systems, +Vantage machines have integrated torque and angle monitoring, protecting against dangerous errors that could result in a recall. Such systems include customizable torque sequences for an even preload distribution. Finally, post-torque inspection acts as a final safeguard against sub-par components winding up in a vehicle.

Press Systems

Press-fit technology is an essential aspect of automotive component manufacturing, specifically for electrical and mechanical connections where temperature fluctuations, shock, vibrations, and contaminants are a major concern. Manufacturers can even use it to create a simultaneous electrical and mechanical connection in a single process step. However, it also requires the right tools to do it properly, and that’s where +Vantage comes in. Our machines can utilize servo, hydraulic, air-over-oil, or pneumatic press systems to integrate the best system for a given application.

Naturally, a solid connection means proper force applied correctly, and integrated metrology answers those needs. Our force/stroke monitoring allows manufacturers to track the press curves output function, creating detailed data for the process. Finally, the in-line post-press inspection verifies the quality, minimizing the need for operator input.

Glue and RTV Dispensing

Windows and windshields require delicately applied adhesive to sit firmly and securely in a vehicle. +Vantage offers comprehensive RTV dispensing systems to meet this need, utilizing servo or robot-assisted application. Application systems include internal monitoring systems and advanced 3D visual inspection capabilities to check bead quality.

Rivet Systems

Blind rivets are popular in the automotive industry for assembling structural elements such as the chassis, door hinges, seat structures, and other vehicle parts. These processes require precision paired with high force to ensure a secure connection every time, and robots offer a robust solution. +Vantage’s automated systems can use blow-fed in-line riveting to provide unmatched line speed and eliminate the downtime to reload.

Automate With Us!

Are you ready to revolutionize your manufacturing assembly process? To learn about the detailed +Vantage integration process and the vast array of automation services we offer, download our brochures!

To discuss how our systems can benefit your custom process, contact us to speak with an engineering design consultant today!