25055 - Robotic station for bonding heating mats to car seats

The Robotic Station for Gluing Car Seat Heating Mats is designed for the automated application of adhesive onto foam car seat components. The device ensures precise application of the bonding agent onto cushions, backrests, and other interior trim elements with diverse geometries. The machine’s design allows for the rapid implementation of new parts, provided they fit within the working area and use dedicated tooling (mounting pallets).

Operation Description

The cycle begins with the operator loading a component onto the pallet nest in the extended drawer. Once the part is positioned, the operator initiates the process by pressing the "Start" button. The system verifies the status of positioning sensors via the HMI panel; in the event of an error, the operator receives precise information on which point requires correction. The process can only start if the rotary table lock is active.

After parameters are confirmed, the drawer moves into the robot’s working zone, and the safety shutter closes. The robot applies the adhesive spray according to a programmed path, then returns to its base position (HOME) or – in dual-station mode – proceeds to service the second drawer.

Upon completion of the application, the shutter opens and the drawer returns to the operator. This is followed by a visual inspection and the installation of additional components (e.g., heating mats). At this stage, the operator can release the table lock to freely rotate the part. By using two drawers, the loading and gluing processes occur alternately, eliminating downtime and optimizing cycle time.

Machine Construction

The core element of the station is a KUKA KR 10 R1440-2 industrial robot equipped with a Graco spray system. This configuration guarantees application repeatability and flexibility in handling multiple production variants.

The transport system is based on two pneumatic drawers that separate the human workspace from the robotic area. The adhesive supply is gravity-fed via an automatic lift that raises the containers from floor level to working height. The station also features an integrated water gun-flushing system and a drain for condensate and process residues.

Key modules include: