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Manufacturing truck cabs differs significantly from that of producing cars, presenting a number of unique production challenges. With cycle times much longer than those typically seen on a car production line, several different tasks and processes must be performed by the same robot(s) if the highest efficiency levels are to be achieved. This means that the robots must be capable of reliably exchanging different tools and processes in a time efficient manner using automatic tool changers.
Although this Volvo Trucks plant had long-term experience with robot tool changers, the plant suffered from ongoing reliability issues associated with these systems, requiring significant resources from the maintenance department. This therefore was the catalyst for seeking a more robust and reliable solution.
With around 60% of all robots within the plant fitted with automatic tool changers, productivity is closely linked to the reliability of these key items. A key objective was improving electrical connections and reliability associated with sensitive signals. Volvo agreed to subject Stäubli’s MPS System to a comprehensive series of tests to evaluate performance and measure reliability over an extended period. Initial trials on the MPS Robotic Tool changer were performed offline, with the criteria being set of achieving 30,000 cycles with no faults.
Upon achieving a total of 42,000 cycles with no failures or faults, over a period spanning some 8 months, the decision was made to put the same tool changer unit on line for further evaluation. The MPS system was integrated to the robot on the line which performed the most demanding tasks, and most frequent tool change cycles, a true test of the build quality and performance of the Stäubli tool changer.
The exceptional reliability of Stäubli’s MPS robotic tool change system during the rigorous on-line production trial was such that the decision was made to use the Stäubli solution on all 64 robots within the new body in white line installed in 2021. The MPS robotic tool changers are used in conjunction with spot welding guns, seam sealant dispensing systems and gripper systems used to handle and transfer different truck cab components during the production process. Stäubli robot tool changers in these applications are working with robot payloads of between 200 and 500kg.
Media and signals handled by the robotic tool changers include high current – 120amps – for spot welding operations, sensitive signal data, and water and air services. The self-cleaning pins and MultiDnet quick-change contacts on Stäubli’s electrical connection modules also made a significant contribution to achieving the reliability and consistent connectivity demanded by Volvo Trucks.
This Volvo Trucks factory is located in Blainville, France. The plant, which has some 1,900 employees, performs a wide range of metal pressing, welding, painting, and trimming operations required for the production of all Renault Truck cabs and Medium Duty, and Medium Heavy Duty Volvo Trucks cabs. In addition, the facility also has a contract with DAF to build their Medium Duty and Medium Heavy-Duty range of truck cabs. Since 2021, this facility has also undertaken serial production of electric vehicles used for distribution purposes.
Wilfried Graindorge - Robotics Technician - Volvo Blainville
