Objectives
The objective of this project was to automate the precision glue application process for the rear lights of a high-performance hypercar. The client required a solution that could enhance both the accuracy and efficiency of the adhesive application, which is crucial for the structural integrity and aesthetics of the rear lights. Additionally, the automation setup needed to be collaborative, allowing for seamless interaction with human operators without compromising safety. By implementing automation, the client aimed to improve consistency in product quality, reduce manual labour, and increase overall production speed without sacrificing safety or control.
Solution
To address the client’s needs, we integrated a Universal Robots (UR) collaborative robot (cobot) with an advanced automated glue applicator. The cobot was programmed to precisely apply adhesive to the rear light assembly with high repeatability and accuracy, ensuring that the glue distribution met the exacting standards required for hypercar components. Key elements of the solution included: Collaborative Robot Integration: The UR cobot was chosen for its versatility, ease of programming, and proven record in collaborative environments. This allowed human operators to work safely in close proximity to the robot, ensuring flexibility in the assembly line without the need for extensive safety barriers. Automated Glue Applicator: A specialised glue dispensing system was integrated with the cobot, calibrated for optimal adhesive flow and accuracy. This setup ensured that each rear light received a uniform adhesive layer, enhancing both the durability and appearance of the final product. Safety and Compliance: To ensure compliance with safety standards and protect human operators, the cobot isequipped with force-sensing technology and programmed with limited speeds and safe operating zones. This configuration allowed the cobot to automatically stop if any unexpected interaction with a human occurred, thereby safeguarding operators while maximizing efficiency. The automation solution resulted in a highly accurate, repeatable, and efficient adhesive application process, reducing waste and enhancing productivity, while maintaining a safe and collaborative workspace for human operators.
Benefits
- Operators could work alongside the application, reducing the need for complex guarding and lowering
- Enhanced quality assurance ensured uniform coverage and impeccable quality.
- Increased production rates enabled the client to meet demand more efficiently.
- Improved safety measures reduced the risk of workplace accidents and injuries.