Motoman Robots Handling, Assembling, Testing and Packing

Modular, highly flexible system uses three Motoman HP6S robots in one cell and one HP6S robot in another, to perform multiple processes required to assemble LED lamps for semi-trucks, trailers and off-road equipment.OTR Vehicle Lighting Systems

Highly flexible system produces parts approximately 25%-30% faster. Cycle time reduced from 19-24 seconds per part manually, to 12-16 seconds per part with the robots, depending on part type. Each cell can run 10 different product types, each with two color variations. Total of 60 part numbers possible per cell. Parts can be packaged to order in three different types of pack media. Changeover between part runs is <5 minutes. Robot system requires two operators versus four or five needed for manual processing. Looping process allows operators to load multiple stations. Operators are removed or distanced from fumes. New processes (new encapsulant, new non-contact solder method, and “plug and play” application of support equipment) enabled tremendous material savings and improved part quality and aesthetics.

Project Challenges

Motoman Robotics Solution

Motoman Robotics provided a highly flexible system consisting of two independent cells: Cell #1:

Fixtures/Tooling Details

Motoman Robotics provided custom end-of-arm tooling consisting of mechanical grippers with quick-change fingers. Robot sensors on gripper verify that finger type matches the part type to be run. Additionally, Motoman Robotics provided part fixtures used on the rotary table and a special testing fixture that can accommodate all part types. Sensors on the robot gripper also verify welding fixtures on the welder.