Success Story

Roller Hemming Door Entrance Porsche

Our standardised hemming technology and industrial image processing components ensure an innovative approach to the hemming of door- steps and frames in car body construction, making us the market leader in this field.

Initial Situation

As a result of the lightweight construction strategies of vehicle manufacturers, outer parts made of aluminium are increasingly being combined with high-strength structural parts. This makes classic welding impossible. Therefore, cold joining processes such as roll hemming are increasingly being used. The process however requires a precise positioning of the vehicle in order to exclude process errors and wastage. The customer’s line should be able to produce up to 7 different types.

Implementation

Depending on the opening angle of the hem, the system is comprised of one or two stations, each with four KUKA heavy-duty robots. Each robot is equipped with one of our standardised hemming tools. To optimise the robot position, we use our AI° VISIONSCANNER2, which is attached to two robots in the station. Each of these scanners capture certain features of one side of the vehicle and calculate a 6D correction value for the robots. Subsequently, each robot retrieves this 6D correction value from the respective sensor allowing it to carry out precise roll hemming operations.

Client Value Proposition

Due to the high degree of standardisation in our systems, no changes to the hardware are required once a basic installation of the robots and tools or sensors has been carried out. Further integrations are done solely through by means of changes in the software. Compared to conventional systems, up to 90% of the investment costs and implementation time can be saved.

Methodology

Robot-guided roller hemming with double roller hemming tool FW 270. Robot position optimization by lasertriangulation with VISIONSCANNER2 from AI°.

 

Parameter

  • Cycle time 102 seconds
  • Measuring speed 200ms
  • Integration of 7 types

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