For in-line manufacturing, it was necessary to meet a cycle time specification for the gluing process that would be within at least two seconds of the cycle time of the injection molding machine. For each vehicle set there would thus be a maximum of 60 seconds available for the entire gluing process. Despite the short cycle time, gluing tolerances of +/- 1.5 mm had to be observed in order to guarantee optimal joining quality when gluing the part to the vehicle.

Gluing of automotive add-on components: a growing trend

By using the freely programmable jointed-arm robot, the system is flexible, such that it can be converted without problem for other products or face-lifts. This represents a major financial advantage for the customer, who will incur only a third of the costs that would otherwise result for the conversion necessary for subsequent models. This saving can either be passed on to the end customer in the prices of the parts, or else increases the profitability of the system.

The production process of the system can be outlined as follows:
At the beginning of the process an operator places a set of body side moldings in a loading fixture. With a vacuum gripper the robot now picks up of the set of body side moldings. As the radius of action of the six-axis robot covers more than 360°, it can take the strips to all the necessary peripheral units and process them with a tolerance of +/- 0.5mm. Once processing is complete, the product is set down and a new one is picked up.

Through the optimization and the further improved harmonization of the processes and systems, it was possible not only to refine the gluing processes but also to reduce the cycle time to 38 seconds.

• KR 45 six-axis robot
• Transfer fixture
• Gluing head with unwinder for longitudinal adhesive tapes
• Linear gluing module for short adhesve tape strips
• Adhesive tape punch for form pads

• Outgoing conveyor