The carpets enter the cell on a rotary table equipped with three fixtures. The coding on the fixtures tells the robots which cutting pattern to use. The four robots work in parallel, always two to a carpet. As soon as they are finished, the fixture moves onwards, and either leaves the cell or is transferred to the next pair of robots. One third of the table is always located outside of the safeguarded zone; here the carpets, and if necessary the fixtures, are exchanged manually. In order to achieve maximum output, however, most of the time Trevest uses three of the same fixtures. The flexibility of the system means that the option exists to let a test fixture run through the cell during operation. The test fixture can then simply be programmed into the controller by means of the KUKA Control Panel, thus integrating it into the sequence with minimal effort.

In addition to this robotic cell, which was set up in 1998, there is a smaller one, one year older, which has two KR 15s. This cell’s rotary table is equipped with two fixtures. While the two KR 15s cut one carpet, the second fixture is loaded and unloaded in front of the cell. In addition, since 1995 Trevest has been using the model previous to the KR 15, the IR 364/15, to test new applications.

• Six KUKA KR 15 robots
• Four KUKA KR 364/15 robots
• Six PC-based KUKA robot controllers, including control panel with Windows interface
• Four conventional robot controllers
• Robot programming
• Commissioning

• High flexibility
  
  For Trevest, the main benefit of using robots is their flexibility. The company can handle new shapes and sizes of apertures within about 24 hours; high repeatability can be achieved within a week. As a result, Trevest can respond quickly when model variants are added or when adaptations become necessary. This flexibility is of particular importance when one considers that changes to the cutting patterns generally take place during the start-up phase for the product, when the company is already under time pressure.
  
  
  
• High availability
  
  The robots’ high availability, which is ensured by an efficient after-sales service program, is of fundamental importance to Trevest, considering the automotive industry’s just-in-time delivery practices.
  
  
  
• Optimal use of space
  
  Both the greater maneuverability of the KUKA robots, whose axis 1 can rotate an additional 5° in each direction beyond the usual 360°, and also the space-saving mounting of the fluid supply lines on the robots, contribute to an optimal use of space.
  
  
  

• Remarkable acceleration capacity
  
  The remarkable acceleration capability of the KUKA robots is an essential precondition to achieve the necessary velocity in a short distance. Only in this manner can the specified cycle time be achieved.
  
  
  

• Precise handling
  
  The robots’ precise handling guarantees the required high repeatability.
  
  
  

• Resistant to environmental conditions
  
  All of the axes of the robots are sealed against water spray, thus ensuring that their availability is not affected by moisture.