KUKA Case study \ Automotive

FAW J i ef ang Automoti ve Co., Ltd. Wuxi Di esel Engi ne Works

KUKA Roboter GmbH
Hery-Park 3000, 86368 Gersthofen, Germany, Phone: +49 821 4533-0, www.kuka-robotics.com
PAGE 1 OF 3
KUKA KR 1000 titan
assembles cylinder blocks
at the FAW Group
Use of KUKA robots sets benchmark in manufacture of
heavy-duty diesel engines in China
Largely unknown in Europe, the FAW Group is one of the largest automotive
manufacturers in China. In February 2012, FAW Jiefang Automotive Co., Ltd.
Wuxi Diesel Engine Works, a full subsidiary of the FAW Group Corporation, began
operating a production plant for the manufacture of heavy-duty diesel engines
with a yearly capacity of 125,000 units in Huishan. Robots from Augsburg are being
applied to a wide range of tasks in this plant. The highlight here: KUKA KR 1000
titan's handling of 700 kg cylinder blocks.
Customer
FAW Jiefang Automotive
Co., Ltd. Wuxi Diesel
Engine Works
Applications
Assembly
Fastening,
Inserting, mounting
Other assembly/disassembly
operations
Product
KR 1000 titan, KR 500
Heavy-duty (360-1000 kg)
KR 210
High payloads (100-240 kg)
Sectors
Automotive manufacturers
KUKA Case study \ Automotive
FAW J i ef ang Automoti ve Co., Ltd. Wuxi Di esel Engi ne Works
KUKA Roboter GmbH
Hery-Park 3000, 86368 Gersthofen, Germany, Phone: +49 821 4533-0, www.kuka-robotics.com
PAGE 2 OF 3
Starting point / Task definition:
Weighing up to 700 kg, the need to rotate the cylinder block of a 6DM diesel engine
(for example, for the assembly of a cylinder bank, crankshaft and oil pan) presents
particular challenges on the assembly line. Conventional handling with rotary
and lifting devices as well as adequate manpower was not possible due to space
requirements and a lack of efciency. The combination of a workpiece weighing
between 500 and 700 kg and a 200 kg gripper means only a heavy-duty robot with a
1000 kg payload capacity can be considered for this task.
Implementation / Solution:
As soon as the cylinder block, weighing 500 kg before assembly, reaches the work
island, the KUKA KR 1000 titan picks it up under sensor control and sets it down
on a workpiece carrier. From here, the cylinder block passes through several work
steps, including the installation of connecting rods, cylinders, oil pans, etc. During
this assembly work, the robot must rotate the cylinder block exactly 90 degrees
at a dened point. Upon completion, the cylinder block - now weighing 700 kg - is
brought back to the island station where the KR 1000 picks it up and performs a
180-degree rotation to set it down on the workpiece carrier. The assembled block
then continues its journey through the assembly line.
Controllers
KR C2 (Robot Controller)
Implementation
2013
KUKA Case study \ Automotive
FAW J i ef ang Automoti ve Co., Ltd. Wuxi Di esel Engi ne Works
KUKA Roboter GmbH
Hery-Park 3000, 86368 Gersthofen, Germany, Phone: +49 821 4533-0, www.kuka-robotics.com
PAGE 3 OF 3
System components:
The KUKA KR 1000 titan is the strongest six-axis robot on the market. With a
maximum reach of 3,202 mm, a repeatability of 0.1 mm and a payload range
of 1,000 kg, this high-tech machine is the world champion of industrial robots.
Its working envelope encompasses up to 78 m. Besides the KR 1000 titan, two
KR 16s take on challenging sealing applications while a KR 210 and a KR 500 are
responsible for heavy handling and assembly operations. The six-axis KR 210
stands out due to its payload of 210 kg and a reach of 2,700 mm.
Results / Benefits:
The intelligent system layout with the KUKA island station (in a double-X
design) allows for shorter paths within the full assembly line, thus reducing
the number of work carriers, increasing the efficiency of the assembly line
and reducing the investment costs. The robots must also install the heavy
components, at times applying a great amount of force, while causing no
damage to these important parts. Their masterful performance allows
these KUKA machines to complete the challenging tasks with flying colors.
Today, the assembly line has a production output of 125,000 units a year, far
exceeding the 100,000 called for in the original planning.
Find out more about pioneering robotics:
+49 821-4533-0, www.kuka-robotics.com
Here you can find your Sales contact:
www.kuka-robotics.com/en/sales/sales_regions