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Robot sews car seat covers
 
Starting point / Task definition
 

Previously, BMW had all of the main seat components for its cars sewn manually. For the new 7 Series, however, the company planned to carry out a conversion. Higher quality and greater output were required. Only a six-axis jointed-arm robot could come into consideration. Alternative automatic processes were ruled out due to the complexity of the sewing process.
 
 
Implementation / Solution
 
Robot sews car seat covers
Robot sews car seat covers

Today, a KUKA KR 30 robot sews leather covers for seat squabs and seat backs of both basic and multi-function seats for the new 7 Series vehicles. The covers are placed manually on a workpiece carrier in the robotic cell. An optical system scans in the color of the cover and transfers this information to a data storage device on the workpiece carrier. When the carrier reaches the last corner before the robot, a PLC transfers the data to the robot controller, the top thread and under-thread changing stations and the folder blade. If the robot needs a different color thread, or there is not enough thread remaining, the thread has to be changed. To exchange the top thread spool, the robot turns the back of its arm with the spool to the top thread changing station. The station’s handling device removes the spool which is no longer needed and transfers the spool with the new color to the robot. Then the thread remaining in the eye of the needle is spliced to the new thread. After that the KR 30 can automatically pull the entire thread through the eye of the needle. The under-thread is exchanged by an under-thread changing system, which takes the desired spool from one of 16 magazines. First the KR 30 sews the two-dimensional transverse seams. To facilitate this, the leather is arched using the folder blade. The robot then backstitches at the beginning of the transverse seam, sews the rest of the seam, and backstitches again at the end of the seam. Either one or two transverse seams are required, depending on the workpiece. In the next step, the wings on either side of the workpiece carrier fold upwards, together with the leather side pieces. In this position the robot sews the three-dimensional longitudinal seams of the seat cover, likewise backstitching the beginning and end of the seam. Finally, the KR 30 cuts off the end of the thread and secures it in the sewing head.
 
 
System components / Scope of supply
 

  • KUKA KR 30 robot
  • PC-based KUKA robot controller, including control panel with familiar Windows interface
  • Sewing head
  • Conveyor system with eleven workpiece carriers
  • Top thread changing station
  • Under-thread changing system
  • Folder blade
  • Siemens S7 PLC programmable logic controller for control of the overall system
 
 
Results / Success
 

  • High repeatability

    In selecting the robot type, the most important criterion for BMW was repeatability. Lower precision would lead to broken needles and other mechanical damage, leading in the end to lower quality.
  • Short cycle times

    The robot’s short cycle times result in a shorter sewing process.

  • Flexibility

    At present, the robot sews main seat components in five different colors. Since the system is designed to handle 16 colors, a large degree of flexibility is provided.
 
 
 
 
 
Number of report
 
R 215
 
Industry
 
Automotive manufacturers
 
Application
 
Machining
Other machining operations
Assembly
Inserting, mounting
Other applications
 
Product
 
Robots
Medium payloads (30-60 kg)
Controller
KR C (Robot Controller)
 
Customer
 
BMW AG, Dingolfing, Germany
 

 
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