Integrated overall concepts for highly efficient manufacturing processes - this is Dürr's field of activity. The mechanical and plant engineering company, headquartered in Bietigheim-Bissingen, Baden-Württemberg, generates around 60% of its sales with automotive manufacturers and their suppliers - including turnkey systems for automated gluing processes.

... transfers it to the lightweight robot for further processing.

© Kuka

The system concept for automated tank gluing with the sensitive robot is as follows: In final assembly, the skilled worker guides the tank to a turntable with the aid of a manipulator, cleans it, brings it into the correct position and transfers it to the robot for further processing. To prevent the adhesive nozzle from drying out, the application nozzle is located in a sealing agent container. After a signal, the robot moves out of the container to the home position. There, adhesive flows into a collecting container and the adhesive nozzle is cleaned manually. When the starting point at the stationary tank is reached, the nozzle opens under pressure so that no air bubbles are created. The robot then applies the adhesive seam evenly to the tank and uses sensors on the application head to monitor the precise height of the seam.

"Although an adhesive bead can be applied by hand, the result does not come close to the precision of a robot," explains Ahlborn. In contrast to a linear gantry, a robot-based solution can map the three-dimensional complexity of the bead geometry. Thanks to its seventh, co-rotating axis, an HRC-capable robot sticks in a 360° radius without having to reorient itself - and without having to set down. When it has finished its work, the skilled worker takes center stage again by fitting the tank into the vehicle body at the specified position. This complex process still requires the individual skills of the person. The manipulator supports him in ergonomically unfavorable movement sequences.

As there are no fences or enclosures in either bonding process, the safety requirements are high. The entire safety concept must meet strict specifications and standards based on a risk assessment. Among other things, the robot is positioned in such a way that direct contact with humans is minimized as far as possible. In addition, the robot must switch off within milliseconds as soon as contact is detected. The concept for the gluing cells is designed so that the robot always operates below the worker's head and chest area. The application technology - consisting of the lightweight applicator and the lightweight robot - has a large, soft and rounded design so that only low forces are generated when the robot touches the surface.

The first system with the tank application went into operation in March 2016. "Since then, ten systems have already been sold in the bonding area," reveals Ahlborn. Dürr in Bietigheim-Bissingen is therefore optimistic about the future of HRC-capable solutions and is already working on comparable concepts for robot-based gluing of small panes and other components.

Painting together

Dürr and Kuka signed a cooperation agreement at the beginning of May: Together, the two companies want to launch an integrated solution - called 'ready2_spray' - for automated paint application.

Kuka will contribute a small robot from the KR Agilus series to the new system solution, while Dürr will provide the technology for paint application. "The unique selling point is the coordinated and proven components that have been integrated and brought together in an automated painting solution. This is unique on the market," Stefan Lampa, CEO of Kuka Roboter, is convinced.

The paint application technology is available in various equipment versions. The system and its components will be completed at Dürr and put into operation in advance. Among other things, the cooperation agreement regulates development, series production, marketing strategy and the delivery and after-sales processes. The sales concept provides for the robot to be offered on the market by both Kuka and Dürr.