State-of-the-art automation systems for BEV component lines

In the competitive world of automotive manufacturing, innovation and reliability are key to maintaining production efficiency and meeting industry demands. HG Automation needed to overcome supply chain challenges and deliver a state-of-the-art automation system for a Tier 1 customer's new battery electric vehicle (BEV) component line.

From small service provider to full-service integrator

Since 1937, Bulldog Factory Automation has been tailoring factory solutions that improve and make production more efficient. Initially a small service provider for local Detroit factories, the company was purchased by HG Automation (HGA) and is now a full-service integrator providing turnkey solutions for body in white welding at Detroit’s major OEM automaker and Tier 1 supplier facilities. The company maintains a complete complement of automation specialists and experts that make it a prominent player in the automotive, heavy-truck and aerospace sectors, delivering custom-made systems from concept to installation.

Large-scale project on a tight timeline

Recently, HGA’s development and design engineers, automation assembly teams, programmers and installation technicians were all brought to bear when a Tier 1 customer needed a turnkey automation system for a new battery electric vehicle (BEV) component line.

HGA was given a condensed timeline in which to design, build, debug and install a five-zone automation system that incorporated part handling, stud spot welding and adhesive dispensing for a BEV rear quarter assembly. However, when the customer’s usual robot supplier was stymied by supply chain issues, HGA turned to KUKA for help.

“We had been doing small collaborations with KUKA for some time, but this was our first large, turnkey automation project that we deployed with them,” said HGA Senior Business Development Director Aaron Burke.

In addition to a challenging timeline from design to delivery, the project had to meet cost and space requirements. “Essentially, we had to provide a cost-effective, smart solution with the right number of robots and technologies all deployed into as small a package as possible for our customer,” Burke said. “Once we got the customer’s specs, we went through a number of iterations, designing and redesigning the process to get a system that could output the right volume of parts.”

The solution: 86 KR QUANTEC robots

The KR QUANTEC series consists of all-purpose, six-axis robots with payloads of 120-300 kg which allow the versatility to reliably handle a variety of production applications. The series is also very adaptable to cost-effective cell planning, which fit precisely into HGA’s requirements.

“We needed to meet space, volume and aggressive cycle times, along with other criteria, and KUKA robots allowed us to do that,” said Andrea Conover, HGA manager of Program Management, who served as the project manager. “KUKA robots also have great track records of uptime and limited maintenance on the line.”

Assembly line complexity

For the body assembly process, the QUANTEC robots handle over 30 individual parts and generate more than 300 welds. In complex synchronized movements, they pick parts, transport them to stations where they are welded together, perform a variety of other spot and stud welds, apply adhesives and unload bodies onto rack stations. In addition to robotics, the system includes technology for trays, conveyors, trunnions and buffer zones.

Integration Support

Designing and assembling such a complex system was an inherently challenging task that occasionally presented obstacles the HGA team had to overcome. KUKA’s responsiveness was another prime component to the project’s success, according to the team.

“While we were debugging the line, we needed support,” Conover said. “KUKA always responded quickly and was onsite immediately to help us out. That support allowed us to maintain our tight time schedule and good relationship with our customer, so everyone’s end goals were met.”

Ease of Integration with KUKA.WorkVisual

In addition to meeting the system’s performance requirements and KUKA’s support during the implementation process, the ease with which the HGA team was able to program the robots was another feature that figured prominently in getting the line up and running on a challenging time schedule. Programming the robots for the many precision assembly tasks was simplified with KUKA technology. For instance, HGA robot programmer Jared Witt used the KUKA.WorkVisual engineering suite software to program and configure the KR QUANTECs and said that the overall ease of use during the programming process also kept the project on schedule.

The KUKA.WorkVisual engineering suite is a comprehensive tool for configuring, programming, and diagnosing KUKA robots. KUKA.WorkVisual integrates all steps of the engineering process into a single interface for a seamless workflow. The suite allows users to program and simulate robot motions, test sequences, and optimize performance before deploying robots on the production floor. KUKA.WorkVisuals’s intuitive design and extensive functionality significantly reduce setup times and improve overall operational efficiency.

Additionally, KUKA.WorkVisual program code is checked for logic in the background while programming steps are being carried out. As a result, errors are caught early on, which allows projects to be implemented quickly and consistently.
“This was my first programming experience with KUKA,” Witt said. “The KUKA.WorkVisual along with the KR C5 robot controller helped tremendously in reducing the debug time on the system. I was able to write logic out beforehand and work out all the issues prior to commissioning. Other brands don’t have a program that is as comprehensive.”

A Successful Partnership

Enabling HGA to get its customer’s line into production within the challenging timeline along with the substantial technical support and technology KUKA provided on the project solidified the two companies’ association for the future.

This project has been a great experience for us. KUKA and HGA have developed a solid relationship with one another, and we’ve even started leapfrogging into other areas as a partner in different solutions. That benefits both of our organizations.

Aaron Burke, HGA Senior Business Development Director