Automotive Success story

Safety first

Customer benefits
  • Error-free assembly of sensitive safety systems
  • Future-oriented, easy-to-adapt plant concept
  • Integrated quality assurance
  • Traceability and documentation
  • Enhanced productivity and profitability

TASK

Error-free assembly of ABS systems

Automotive manufacturers are demanding ever greater precision from the ABS (Anti-lock Braking Systems) they install. A multi-national ABS manufacturer with manual assembly lines in its factories in China, Germany and the USA could no longer meet these stringent requirements. Robot-based automation solutions were seen as the way to open up new dimensions in terms of quality and cost-effectiveness.

Advanced Automation Inc. of Greenville, South Carolina, was entrusted with this challenging task. The experienced system integrator opted for Stäubli as its robot supplier. One of the main reasons for this decision given by the project leader was that the level of precision achieved by Stäubli robots far exceeded the market standard. Indeed, these industrial robots are considered the first choice for assembly processes demanding accuracy in the micrometer range. And, of course, Advanced Automation did not want to take any risks in the assembly of the highly sensitive ABS systems.

 

SOLUTION

Full automation of all steps in the process

The solution implemented by Advanced Automation is characterized by the full automation of every single step throughout the entire assembly process. The production of anti-lock braking systems runs on three different assembly lines. Stäubli six-axis robots of the RX160 and TX90L series take on handling tasks of all kinds during the measuring up, screwing and assembly stages of the process.

The system integrator has put a great deal of know-how and experience into operational design. Even complex processes have been refined to the extent that the robot does not have to release a component in order to adjust its grip on it. The reasoning behind this is clear: any reorientation involving temporary release would eat up valuable fractions of a second and frustrate the quest for the shortest cycle times. Thanks to an ingenious gripping technique and to