Volvo CE invest in Smart Manufacturing in a new pilot project

17.12.2018

Smart manufacturing and robotization are becoming increasingly common in Swedish industries. Volvo Construction Equipment is at the forefront of this development and is now investing in a pilot project that will streamline the production of low volume items and reduce production costs.

Many manufacturers in the automotive and manufacturing industry have items that are to be produced in low volume, but in several variants. It often requires access to custom machines, jigs and fixtures that are not used for some time or that take a long time to change, which is costs intensive. Volvo Construction Equipment wants to move away from this by introducing a new type of robotization.

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"We have developed a solution that is able to use the same equipment for many different items and in the fall, we started production with a pilot project. We will work with a robot cell and use the Delfoi Robotics offline programming system, says Erik Åstrand, weld optimization specialist at Volvo CE.

”Jigless” welding

he pilot project will focus on the manufacturing of components for Volvo CE’s Articulated Haulers in Braås. The optimization involves introducing "jigless " welding in production, i.e. welding is carried out using flexible robots instead of customized jigs or fixtures. jigless" welding in production, i.e. welding is carried out using flexible robots instead of customized jigs or fixtures.

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                                                   In this concept, plates are delivered into the cell
                                                   and out comes a finished part after the robots 

                                                built and welded it together.                                                                                                                                           Picture: Goodtech Solutions Karlstad / Volvo CE

"In the robot cell, we have a handling robot and a welding robot that build the parts together. The handling robot picks up and places plates while the welding robot welds them together and then we continue one plate at a time until the item is complete, says Åstrand.

Mainly, it is about items up to about 60 kilos, but in the long run the concept can also be an integral part in the production of major components such as vehicle frames. Maximum manufacturing flexibility also requires the fast creation of programs when the robots weld a new item. There, Delfoi Robotics's offline programming system plays a key role. 

Offline programmimg

Offline programming means that the robots are programmed in a computer environment without disturbing the process. This reduces the number of production stops and reduces production costs. Delfoi Robotics is the world leader in the field of welding, which made them an obvious choice of supplier.

"We wanted the best technical solution and software that is compatible with as many robot brands as possible. Delfoi's system is very visual and intuitive to program," says Åstrand.

The robot cell in Braås will be used for 30 low volume items in a continuous one-piece flow without any set times. If the pilot project goes well, the plan is to apply the same manufacturing principle to more products and other Volvo CE plants.

Read more about offline programming and robotization.

This article was first published on Temaindustri.

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