Automotive Chassis and safety

Automation solutions for car body and passenger safety

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Laser cutting of body panels, coating of headlamp lenses, milling of composite front aprons, high tech assembly of ABS systems, zero-defect production of airbags – the scope for deploying robots in the areas of bodywork and safety is almost endless.  Stäubli robots are proving their worth in all conceivable applications where there is no room for error. The strengths of the four-axis and six-axis machines – precision, dynamics, trajectory control and reliability – are the prerequisites for viable solutions in these sensitive areas.

Success stories
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Full processing of injection-molded parts with two robots (WHS Plastics)

A British plastics processor has invested heavily in the full processing of components by robots alongside the presses. The concept has been so successful that the robot is now part of the package with every new injection molding machine ordered.

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X-ray inspection for zero-defect production (Kiekert)

Czech manufacturer Kiekert produces around 180,000 motor vehicle locks per day. An intelligent robotic cell for in-line X-ray inspection, featuring a Stäubli TX60 six-axis robot, ensures the highest quality standards.

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Use of robots for prototype and small batch production (Darne)

A Spanish manufacturer of lightweight components for motor racing was reaching the limits of what could be achieved with its existing three-axis machine. The solution, which adds flexibility, cost-effectiveness and design freedom, came with the purchase of a Stäubli robot.

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TX200 HSM (High Speed Machining)
Robot-assisted machining of molds (Audi)

At the highly advanced Audi Competence Center for Plant Equipment and Forming Technology, the company is working towards digitally linking all processes.  A robotic machining center now replaces four radial drilling machines in the manufacture of molds.

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Stäubli RX160 robot
Laser cutting of B-pillars (Hyundai)

Experts disagree on the best way to cut body panels. Many are content with a standard laser setup, but others progressed to the next level of working with robotic systems. At Hyundai, they have had only good experiences with laser cutting robots.

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Stäubli RX160 and TS60 robots
Production of brake light switches (TRW)

Automotive supplier TRW produces eight million brake light switches a year for Volkswagen Group. To optimize production, TRW turned to Stäubli for its expertise as well as its TS60 SCARA and RX160 6-axis robots, two ultra-high-precision robots.

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Laser cutting with a RX160
Laser cutting for buses (Yutong)

Chinese manufacturer Yutong Bus churns out over 340 units a day and relies on Stäubli RX160L robots for its laser cutting operations. This top-mounted 6-axis robot delivers efficiency, speed and precision.

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Stäubli TX200 and RX160 robots at ACL
Robot machining of aluminum profiles (ACL Automotive)

Competitive pressures are always driving new concepts in manufacturing. The Czech supplier ACL Automotive has entrusted the machining of roof rails to Stäubli robots and is very satisfied with the results.

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Stäubli TX200 hsm robot at Polytech
Machining of front and rear aprons (Polytec)

While the development of composite exterior parts for vehicles takes place on computer systems, production is still dominated by manual labor. An Austrian manufacturer has made the switch to robot processing and is delighted with the results.

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Stäubli FAST picker TP80 and TX200 robots at Cevotec
The next generation of additive manufacturing (Cevotec)

The Fiber Patch Placement (FPP) systems developed by a Bavarian technology company constitute a step change in additive manufacturing. Thanks to high-performance robotics, the process has the potential to revolutionize the series production of geometrically complex lightweight parts in the automotive industry.

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TX90 robot assembles anti-lock braking systems
Assembly of ABS systems (Advanced Automation Inc.)

Automotive manufacturers are demanding greater precision from anti-lock braking systems. These exacting specifications can no longer be met with manual assembly lines. Robot-based automation solutions opened up new dimensions in terms of quality.

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Stäubli RX160 Paint robots
Coating of headlight lenses (GfO)

Currently, all plastic headlamp lenses come with a protective coating. Thanks to the latest generation of robots, transparent micrometer-thin protective layers can be accurately applied under cleanroom conditions.

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