Motoman Robot Laser Cutting Automotive Vehicle Frames

Motoman LaserWorld system uses a six-axis SK16X robot on a shuttle track to accurately cut automotive frame components.

Summary

Easily achieved customer's required production rates. Met customer’s requirements for cutting tolerances.

Project Challenges

Provide flexibility to laser cut 16 different parts numbers of galvanealed tube, 1.245-2.032 mm (0.049"-0.080") thick, for right- and left-hand automotive frame components. Longest parts are 2,375 mm (93.5") long.
Cut holes and slots in 2,000 sets of frames per year.
Achieve trim tolerances of ±1.0 mm (±0.0394"); hole sizes of ±0.4 mm (0.0157"); and hole location tolerance of ±0.25 mm (0.0098").
Change (Customer supplied) fixtures every 50 parts, with fixture change to be completed in a half-hour.

Motoman Robotics Solution

Motoman Robotics provided a modified LaserWorld 6016 system with custom fixtures, including:

One Motoman SK16X robot with dual-channel XRC 2001 controller. Additional features: Expanded Memory, Expanded I/O, MotoCal Robot Calibration, FORMCUT Function, and Macro Job Function.
Servo track for robot with 3-meter stroke/travel.
1000-Watt Nd:YAG laser package with focusing head, Laser diode pointer, water to air chiller, and PC with modem.
Customer-provided compressed air assist gas at 100-110 psi.
MRM2-500 dual ferris-wheel positioner headstock/ tailstock positioner with 500-kg (1,100-lb) capacity per side, 3.5-m (11.48') span between headstock/tailstock faceplates, and 8-10 second sweep time.
Allen-Bradley SLC 5/03 Programmable Controller with PanelView 600 operator interface.
Class 1 light-tight 3.7-m L x 3-m W x 3.96-m H (22' L x 12' W x 12' H) enclosure with patented safety features, fluorescent lighting, safety-interlocked access door, black-and-white camera and monitor package for process monitoring, laser emission status indicator, wire ways and cable trays within cell enclosure. Light curtain protects operator load station.
Customer supplied exhaust system.

Fixtures/Tooling Details

Customer supplied 15 different sets of manually clamped fixtures. Individual sets are located on a common tool mounting spanner using a unique locating scheme. Sensors identify the fixture set and indicate part presence and clamp conditions. The PanelView displays fixture status. The PLC automatically selects the proper program.