Magna upgrades production robots: achieving improved yields and cost savings

Citation

(2000), "Magna upgrades production robots: achieving improved yields and cost savings", Industrial Robot, Vol. 27 No. 1. https://doi.org/10.1108/ir.2000.04927aaf.002

Magna upgrades production robots: achieving improved yields and cost savings

Magna upgrades production robots: achieving improved yields and cost savings

Keywords: Robots, Spray coatings

Magna Interior Systems has installed two new generation ABB TR510 electric robots at its factory in Bitton, near Keynsham, Bristol, for use in the production of door panels for the Rover 75 executive car. A specialist supplier to the automotive industry, the company produces a range of interior fittings made from pre-formed substrate panels, which are then covered in high quality fabrics and vinyls to match the vehicle trim.

Robots perform a variety of operations from the cutting out of profiles to spray coating adhesive onto the panels. Over 350 people are employed at the Bitton plant on a range of shopfloor operations involving skilled assembly work and the tending of sophisticated raw material processes, hydraulic and electrically heated vacuum presses and complex forming tools.

Formerly a paper mill, production at the Bitton plant has progressed over the years, from cardboard suitcase shells to dashboard facias, door panels, rear parcel shelf units and other high quality fittings for various cars including the prestigious Jaguar S-type. Magna acquired the business in 1997 and it now forms part of an international organisation supplying automotive components to customers in the UK and overseas.

In addition to its new investment in additional production facilities for the Rover 75, Magna has also upgraded the adhesive spray-coating cell dedicated to a SAAB door panel line. A single ABB TR510 electric robot has been installed to replace two earlier generation hydraulic robots, which were slow and had become increasingly difficult to service.

According to plant engineer, Mike Redman, Magna is achieving significantly higher production yields of around 98 per cent and with more precise spray control, the new robots are saving around 30 per cent on the consumption of adhesive material.

"We are currently changing over to using water-based adhesive in order to comply with more stringent requirements limiting the use of solvent-based materials. These savings are therefore particularly important not only in reducing operating costs, but also for ensuring that the factory processes are environmentally friendly", he said.

Door panels for the Rover 75 are transported through the spray booth on holding fixtures each loaded with an upper and a lower panel. After being sprayed by the first robot the fixture rotates so that the second robot sprays the reverse side. The cycle time of around 80 seconds is balanced evenly between both robots by loading a reverse set up on each successive fixture.

The cell is fully enclosed with a separate air extraction system. The rear wall of the booth is scrubbed continuously by a water wash designed to catch and extract any over spray particulates for disposal to waste treatment.

After being sprayed with adhesive, the panels pass through a flash off tunnel to allow the water to evaporate before passing on to the next stage where the vinyl foils are pressed on to the panel by a vacuum press.

Figure 2ABB TR510 robot adhesive spraying SAAB 95 door panel

Robots have been used continuously at the Bitton plant for over ten years. The first installation - a waterjet cutting cell is still in service for door panel production. Three other robot installations are used in the production of facias for the Vauxhall Astra. These include an adhesive spray facility, a hot melt glue application operation for the installation of air ducts and a laser-cutting cell for the passenger-side airbag.

A third party systems integrator installed the latter. This cell incorporates an ABB IRB 4400 robot that presents the facia panel up to a fixed laser head. It then tracks around the design profile for the airbag cut out, moving in and out under precise computer control to produce a "hidden" perforation on the backside of the panel (see Figure 2).

For further information contact Jane Attwood, ABB Flexible Automation Limited, Auriga House, Precedent Drive, Rooksley, Milton Keynes MK13 8PQ. Tel: (+44) 01908 350300; Fax: (+44) 01908 350301.