25055 - Robotic station for gluing heating mats to car seats

The robotic station for gluing heating mats to car seats is used for automatic application of adhesive to foam components of car seats. The device ensures precise application of the bonding agent to seats, backrests and other interior trim elements with varied geometries. The machine's design allows for quick implementation of new details, provided that their dimensions remain within the working area and dedicated tooling (assembly pallet) is used.

Description of operation

The cycle begins with the operator loading the component onto the pallet slot in the extended drawer. Once the component is in place, the operator initiates the operation by pressing the ‘Start’ button. The system verifies the status of the positioning sensors via the HMI panel; in the event of an error, the operator receives precise information about which point requires correction. The process can only be started when the rotary table lock is active.

After the parameters have been approved, the drawer moves to the robot's working area and the safety bolt is closed. The robot sprays the adhesive according to the programmed path and then returns to its home position (HOME) or, in dual-station mode, moves on to the second drawer.

After the application is complete, the slide opens and the drawer returns to the operator. A visual inspection and installation of additional components (e.g. heating mats) follows. At this stage, the operator can release the table lock to freely rotate the workpiece. Thanks to the use of two drawers, the loading and gluing processes take place alternately, which eliminates downtime and optimises cycle time.

Device design

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

The transport system is based on two pneumatic drawers that separate the human work area from the robotised area. Adhesive is supplied by gravity thanks to an automatic lift that raises the tanks from floor level to working height. The station also has an integrated water gun rinsing system and a drain for condensate and process residues.

The most important modules are: