Citation
(2002), "New robot welding line sparks impressive productivity gains for GKN Autostructures", Industrial Robot, Vol. 29 No. 4. https://doi.org/10.1108/ir.2002.04929daf.001
Publisher
:Emerald Group Publishing Limited
Copyright © 2002, MCB UP Limited
New robot welding line sparks impressive productivity gains for GKN Autostructures
New robot welding line sparks impressive productivity gains for GKN Autostructures
GKN Autostructures of Telford has installed a new automated manufacturing facility for the assembly of Ford Transit front suspensions, steering arms, dead beams and side members, with a complement of no less than 68 ABB metal inert gas (MIG) and spot welding robots. Efficiency is such that the facility's axle line has already worked up to producing 3,000 units per week.
Even though three separate system integrators have been involved in building the facility, all have specified IRB6400 spot welding and IRB1400 S4C "Arcitec" MIG welding robots throughout.
The IRB6400 is driving up efficiency for GKN through its extremely high mean time between failure (MTBF) rate coupled to a design which, in the unlikely event of a defect, lends itself to rapid trouble-shooting and rectification. Any spot welding cable, for example, can be replaced in less than 15 minutes.
In similar fashion, the IRB1400 "Arcitec" MIG welding robot, with a handling capacity of 5kg, gives spatter-free operation at higher welding speeds, excellent arc stability, easier programming for GKN personnel and a compact, reliable design.
The new line replaces a line of 25 ABB robots, which has been in almost constant use since 1991. The quality and reliability of these robots is such that many of them are to be refurbished at ABB Flexible Automation's UK headquarters at Milton Keynes and then re-commissioned.
GKN Autostructures manufactures parts for the Toyota Avensis and Corolla, Land Rover Defender and Freelander, Rover 75, new Ford Mondeo, Ford Escort and Ford Transit, Nissan, and the Jaguar X400. In total, the division has 193 ABB MIG and spot welding robots installed on these lines (Plate 1).
To keep this army of robots at maximum efficiency, GKN has ABB senior engineer Martin Rutter resident on-site. Martin's responsibilities are both demanding and varied, ranging from "hands-on" overhaul and repair work, on-the-job training, preparing training syllabuses and delivering training to GKN staff on the range of ABB robots in service.
Plate 1 IRB6400
spot welding robot gets to work on the chassis side member of a Ford Transit
"The 25 IRB6s and IRB90s installed on the old Transit line have been outstanding workhorses for GKN, operating three shifts a day, six days a week, for the past nine years. Although it's sad to see the old robots removed, the new generations of IRB1400 and IRB6400 robots are breaking new ground in terms of productivity and reliability for GKN", adds Mr Rutter.
For further information contact: David Marshall, ABB, Auriga House, Precedent Drive, Rooksley, Milton Keynes MK13 8PQ. Tel: +44 (0) 1908 350300; Fax: +44 (0) 1908 350301; E-mail: david.marshall@gb.abb.com