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TASK
Linking geometer and welding stations for the Sprinter NCV3 bodyshells at a major small trucks manufacturer plant. Paneling for the left and right sides. Entire linking process with KUKA robots, skid transport technology and lifting stations. The maximum load to be moved was 1200 kg. The system is designed to produce 30 parts/hour.
SOLUTION
Upper transfer 3 x 2 mirror-image lines between 50 m and 65 m. Special loader with mechanical coupling for elevation and driving drives. Technology based on SEW motors with frequency converter. Reinforced ZP-6 series with integrated rear walking platforms and attached maintenance platforms on the double carriages.
SCOPE OF SUPPLY
On an extended module basis, 6 ZP-6 series lines between 50 m and 65 m were supplied. The design was realised in a reinforced version with 4 to 6 double carriages per line. The two axes are mechanically coupled. All the motors and sensors were included. A special feature is the mutual dual anti-collision protection of the double wagons, which was achieved with mechanical lances and buffers as well as Sick sensors.
In addition, mounted maintenance platforms, special Z-axis protection (Buhl locks) and maintenance platforms were integrated across the lines.
RESULT
The technical requirements with respect to cycle time, mechanical structure (rigidity, strength and bending characteristics) as well as positioning precision fulfil the application requirements to a high degree. The required cycle time of on average 30 seconds per transfer stroke was achieved. Max. strokes of 8 m horizontally and 2.4 m vertically were implemented.
Two lines of the same GÜDEL series were supplied to an affiliated company for a similar application.
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