25011 - Automated ultrasonic processing station for automotive bolster leather
The main purpose of the station is to automate the process of trimming excess material from automotive upholstery components. By utilizing robotics, the solution ensures maximum repeatability and significantly speeds up the production cycle.
Description of operation:
At the heart of the station is a two-position rotary table that enables continuous operation. While the KUKA KR 8 R2010-2 robot performs the cutting process at one station, the operator can safely unload the finished part and prepare the next one at the second station.
Work cycle:
- Loading: The operator places the workpiece in the fixture and secures it with clamps (inductive/optical sensors monitor the correct positioning).
- Start: After exiting the safety zone and confirming the cycle, the table rotates 180°.
- Machining: The KUKA KR 8 R2010-2 robot, equipped with an ultrasonic knife on an angle attachment, precisely reaches all edges of the workpiece.
- Maintenance: An integrated cleaning module continuously removes contaminants from the blade, ensuring cutting quality.
- Completion: The table returns to its starting position, and the finished part is removed.
Device design and main modules:
The design is based on a rigid steel frame that ensures the robot’s operational stability. The entire system has been designed with maximum safety in mind (guardrails, light curtains, LOTO system).
- Central Unit: Machine frame with rotary table drive and roller supports.
- Robotic System: Six-axis KUKA KR 8 R2010-2 robot with an ultrasonic cutter, ensuring a perfect motion trajectory.
- Control system: Electrical cabinet integrated into the enclosure, intuitive HMI panel, and robot controller.
- Safety: Vertical and horizontal light curtains, safety switches, and a lock with a service lockout function.
- Interchangeable tooling:
- BMW G70 reference: Dedicated tool with a clamping system and a module for applying reinforcing foam.
- MB C236 reference: Tool adapted for the simultaneous assembly of a set of parts (left/right).
Benefits for the customer/user:
- Efficiency and precision: Elimination of manual errors and reduced processing time.
- Versatility: Capability to cut a wide range of materials and quick adaptation to new parts.
- Process stability: Consistent cutting quality, independent of human factors.
- Flexibility: Design allowing for easy implementation of new parts while maintaining similar external dimensions.
