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Challenge

Isringhausen GmbH & Co. KG, is the leading manufacturer of seat systems for commercial vehicles in Europe. In March 2006, Daimler Chrysler began serial production of the successor to the reliable “Sprinter” van. Isringhausen, who have been delivering complete seats for the “Sprinter” since 1994, were again involved, and invested in new locations in Germany as well as in their plant in Lemgo, where a new welding shop was built providing additional capacity for joining technology.

Solution

The master plan was broken down into several production lines: seat upholstery (components and upholstery) and frame, where MOTOMAN robots are utilised in a variety of ways in the production processes. The “seat upholstery components” production cell comprises a UP50N robot with an integrated projection welding machine and vibratory conveyor for the welding nuts. The UP50N is equipped with a gripper that takes different components from the conveyor belts and then positions the parts to be welded under the stationary welding machine and puts them back after the joining process. The “seat upholstery” production system contains a 2-station positioner (RWV2 M1) with EA1900N welding robot and a ES165N robot for handling. The 2-station positioner allows the operator and the robots to work in parallel - while the operator is loading the fixture, the robots weld synchronously. The pre welded component is then removed by a ES165N robot which pass it to the other EA1900N robots that process the remaining welding seams while the component is moved in the work area by the ES165N (jigless welding). Here the multi robot synchro function of the NX100 controller is used. This software function was developed specially for jigless jobs with several robots, which allows work to be done in a very compact area because everything is managed from a single controller. This takes away the conventional I/O blocking, and “arm cubes” can be formed to avert collisions between the robots. In the seat frame production cell a operator loads the 3-station positioner (RWV-3) and all the individual parts are secured. The table indexes and the components are welded by the spot welding robot ES165N. Other ES165N robots are used to remove the component from the fixture and to finish the spot welding with fixed welding guns. The feet are welded on a separate fixture that is automatically rotated into the robot's range.

Results

Several robot production cells now work at peak production operating three shifts per day at Isringhausen. The welded seams are also checked by a camera system in a PC based control system that records system status, error messages and quality parameters. All data is available from a main computer for authorized personnel. “The intensive planning and co-operation at the start has shown that with well thought out processes we can keep jobs in Germany and still remain competitive” commented Willi Stadhaus from Isringhausen's production planning division.

Motoman welding robots at Isringhausen

Customer

Isringhausen GmbH & Co KG

Product

Car seats

Country

Germany

Industry

Automotive industry

Application

Arc welding
Spot welding
Handling


System Components

MOTOMAN ES165N robot
MOTOMAN EA1900 robot
MOTOMAN RWV2 2-station positioner
MOTOMAN RWV3 3-station positioner

Contact

YASKAWA Europe GmbH

SHORT FACTS

Robots streamline seat production