Flexible punching system using industrial robots for automotive panels

Yin, Guang; Zheng-He, Zhu; Gong, Hu; Lu, Zhenfeng; Yong, Huashan; Liu, Lei; He, Wei

doi:10.1016/j.rcim.2017.11.002

Cited by 11 publications

(6 citation statements)

References 12 publications

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“…This is also connected with the implementation of additional sensors and detectors, elements of electronics, as well as the application of specialized software, and also the necessity of performing numerous tests and trials [ 14 ]. The attempts at introducing automatization and robotization of hot forging processes, in the case of using at least a part of the outdated machinery park, are even more difficult [ 15 , 16 ]. At the same time, at every stage of the technological line, there is a potential risk of the occurrence of a defect/problem lowering the quality of the products or causing unfulfillment of the geometrical or microstructural requirements (improper structure after forging, inappropriate hardness, etc.…”

Section: Introductionmentioning

confidence: 99%

Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling

Hawryluk,

Dudkiewicz,

Polak

et al. 2024

Materials

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The study refers to the application of numerical modeling for the improvement of the currently realized precision forging technology performed on a hammer to produce connecting rod forgings in a triple system through the development of an additional rolling pass to be used before the roughing operation as well as preparation of the charge to be held by the robot’s grippers in order to implement future process robotization. The studies included an analysis of the present forging technology together with the dimension–shape requirements for the forgings, which constituted the basis for the construction and development of a thermo-mechanical numerical model as well as the design of the tool construction with the consideration of the additional rolling pass with the use of the calculation package Forge 3.0 NxT. The following stage of research was the realization of multi-variant numerical simulations of the newly developed forging process with the consideration of robotization, as a result of which the following were obtained: proper filling of the tool impressions (including the roller’s impression) by the deformed material, the temperature distributions for the forging and the tools as well as plastic deformations (considering the thermally activated phenomena), changes in the grain size as well as the forging force and energy courses. The obtained results were verified under industrial conditions and correlated with respect to the forgings obtained in the technology applied so far. The achieved results of technological tests confirmed that the changes introduced into the tool construction and the preform geometry reduced the diameter, and thus also the volume, of the charge as well as provided a possibility of implementing robotization and automatization of the forging process in the future. The obtained results showed that the introduction of an additional rolling blank resulted in a reduction in forging forces and energy by 30% while reducing the hammer blow by one. Attempts to implement robotization into the process were successful and did not adversely affect the geometry or quality of forgings, increasing production efficiency.

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Section: Introductionmentioning

confidence: 99%

Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling

Hawryluk,

Dudkiewicz,

Polak

et al. 2024

Materials

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show abstract

“…The use of robots in the automotive industry is also quite common, performing quite well in different stages of vehicle production and assembly [36,37]. However, the implementation of robots is not always the best case, as several studies show that, in some cases, a correct use of automation can improve productivity and reduce cycle times, without the need for expensive robotic solutions [24].…”

Section: Introductionmentioning

confidence: 99%

Developing a Novel Fully Automated Concept to Produce Bowden Cables for the Automotive Industry

et al. 2022

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The automotive industry is one of the driving forces of the global industry; thus, it is a very competitive sector which creates a constant need for process improvement, regarding productivity, quality, and flexibility. Automation has proven to be a viable solution for these production problems, with the rising adoption of these automated system by companies that try to design and implement more flexible systems, while reducing costs and improving process quality. Furthermore, the use of automation reduces the manpower factor and its associated variability. In the present work, a new concept for a Bowden cable production process is presented by employing the design science research (DSR) methodology. The project starts with the analysis of the previous production concept, determining possible problems and improvements, as well as setting objectives/requirements for a possible new concept/equipment. This information was used to develop a new automated Bowden cable production equipment, implementing several changes to the old concept and filling a gap in the literature in this field. The developed system was implemented and tested. A considerable reduction in cycle time was registered by 25%, which resulted in an increase of 30% in process productivity.

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“…Barbosa et al [31] developed a new completely automated concept of feeding parts and tool in the milling process, which allows the exchange of products and tools in a perfectly automated way, and according to instructions received from a central computerized system, thus allowing total flexibility of the manufacturing process. Regarding the use of robots in the production of automotive parts, Yin et al [32] proposed a flexible punching system based on industrial robots to produce automotive panels, combining a special punching plier and industrial robots. The proposed system is modular and more flexible and efficient, effectively reducing the production cost of automotive panels.…”

Section: Introductionmentioning

confidence: 99%

A Novel Automated System for the Handling of Car Seat Wires on Plastic Over-Injection Molding Machines

et al. 2021

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The structure of car seats is becoming increasingly complex, with mixing of wire conformation and plastic injection. The plastic over-molding process implies some labor, which can be reduced if novel solutions are applied in this manufacturing area. The handling of the wires used in car seats is the main problem identified in the process, wasting time both in the feeding and in the extraction of the molds used in the wire over-molding process. However, these machines are usually extremely compact and the free space around them is too short. In classic molding injection machines, there are just two half-molds, the female, and the male. In the over-molding process of wires used in car seats, three half-molds are used in order to increase the cycle time. Thus, to solve this problem, the classic robotic solutions are not appliable due to lack of space and elevated cost. This work describes the development of an automated solution able to handle the wires in both the feeding and the extracting phases of the production cycle, avoiding the traditional labor costs associated with this type of machine. Departing from an industrial need, the developed novel solution is described in detail and can be successfully adapted to other situations of low added-value products where it is needed to increase the productivity and competitiveness of the product. The system developed uses mechanical and pneumatic solutions which, combined, can be used to solve the identified problem, occupying a restricted space and requiring a small budget. This solution can be translated into guidelines that will allow the analysis of situations where the same system can be applied.

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Flexible punching system using industrial robots for automotive panels

Cited by 11 publications

References 12 publications

Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling

Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling

Developing a Novel Fully Automated Concept to Produce Bowden Cables for the Automotive Industry

A Novel Automated System for the Handling of Car Seat Wires on Plastic Over-Injection Molding Machines

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