Process Overview
Bigwave Robotics (Marosol) established an automated assembly line for console parts for Kia Motors' newly launched SUV-type electric vehicle.
The existing console assembly line is a large-scale assembly line, requiring an average of 40-60 workers to assemble manually. The lack of automation experience presented challenges in securing space and recruiting assembly workers.
Frequent staff turnover and resulting skill level issues hindered productivity. To address this, the company replaced some workers with robots, addressing the labor shortage and consistently ensuring productivity by adapting to the changing workforce.
Warranty Period
- 1 Year
Performance Year
- 2024
Project Duration
- 4 Months
Project Background and Objectives
- Building a multi-product automated production line and reducing labor costs through robotic automation
- Preventing mis-assembly and mis-assembly using a lot-of-lot system and ensuring traceability
- Remote control and integrated management using SOLlink
Components
| Robot | The line utilizes Seiko EPSON's LS-b series, a proven product that has held the number one global market share in SCARA robots for 12 consecutive years, and the C series industrial robot.
The LS-b series boasts specifications ranging from a payload of 3 to 20 kg, a repeatability accuracy of ±0.02 mm, and a standard cycle time of 0.4 seconds. EPSON specializes in small robots, focusing on high-speed, high-precision, and low-vibration performance. |
|---|
Workflow
| STEP 1. | The new console parts for SUV-type electric vehicles are largely divided into three parts, each operated on a separate production line. The daily production volume for each line is recorded using the LOT system, with the vehicle type and quantity entered. Based on this data, each product is assigned a number and then production is conducted. |
|---|---|
| STEP 2. | The parts that go into each product are set up on the equipment by the worker, and the part information is linked to the LOT system through a barcode to manage inspection of different parts and missing parts. In normal operation, the robot fastens and assembles the product. |
| STEP 3. | The first line is a flow production line utilizing a conveyor, and the production parts include a wireless charger, a cup holder, and a tray for storing luggage. Due to the nature of the product, it is large in size and the fastening location is at the rear, so it was built as a conveyor type line to simultaneously secure operator operability. |
| STEP 4. | The second line is a standalone modular line, which is the largest part of the console parts, corresponding to the body. Since the assembly section is very small compared to its size, it is a line that is operated as a single unit. |
| STEP 5. | The third line assembles the parts that serve as pillars for the console, which is where the most parts are assembled. Unlike the two products above, this line combines three parts into one instead of assembling one part. Since the assembly time and method for each assembly section vary depending on the vehicle option, the equipment was implemented with a modular concept rather than a conveyor type. As products move through each process, the data is tracked and assembled using LOT barcodes to prevent heterogeneous product assembly. Since there are many product assembly sections, this is the section with the most robots. While other lines only perform vertical fastening, the third line also performs lateral fastening, so it also uses the C series, a multi-joint robot. |
※ The content provided by Bigwave Robotics is protected under U.S. and Canadian copyright and intellectual property laws. Unauthorized reproduction, distribution, or use of this content is strictly prohibited.
Recommended Use Cases
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This solution automates the repalletizing process for Atlas batteries produced by Hankook & Company for export. Due to the diverse import pallet specifications, customer-specific palletizing patterns, and product types, the total number of possible scenarios exceeds 200. The goal is to standardize these scenarios and ensure line stability by supporting a throughput of 10 pallets per minute for medium-sized batteries and 6 pallets per minute for large-sized batteries. [Pallet Feeder & Pallet Conveyor] This solution allows for the use of up to five different pallet types per country, ensuring a smooth 10-stack logistics cycle. Destacked pallets are transported to the battery palletizing position and aligned simultaneously. Completed pallets are transported to the discharge position. [Battery Sorter] Batteries fed inline are automatically sorted into 1st, 2nd (series/parallel), and 3rd layers according to the preset palletizing pattern. The robot then discharges the batteries, repeating the initialization process. [Robot Palletizer] Once aligned, the batteries are picked and placed at the palletizing position on the conveyor, repeating the pick-and-place process according to the specified location and number of layers. Honeycomb feeds are automatically inserted into each layer according to the settings. [Honeycomb Feeder & Sorter] Automatically sorts and inserts honeycombs into each layer of NO-BOX batteries.
Yaskawa Industrial Robots + Automatic Foam Placement — Hankook & Company Battery Palletizing Automation Case 🔋🤖
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260706 en_test
This application is an order picking system that optimizes the operation of 10 Eugene Gocart 180 vehicles using the Marosol remote control system SOLlink.
Process Overview
Bigwave Robotics (Marosol) established an automated assembly line for console parts for Kia Motors' newly launched SUV-type electric vehicle.
The existing console assembly line is a large-scale assembly line, requiring an average of 40-60 workers to assemble manually. The lack of automation experience presented challenges in securing space and recruiting assembly workers.
Frequent staff turnover and resulting skill level issues hindered productivity. To address this, the company replaced some workers with robots, addressing the labor shortage and consistently ensuring productivity by adapting to the changing workforce.
Warranty Period
- 1 Year
Performance Year
- 2024
Project Duration
- 4 Months
Project Background and Objectives
- Building a multi-product automated production line and reducing labor costs through robotic automation
- Preventing mis-assembly and mis-assembly using a lot-of-lot system and ensuring traceability
- Remote control and integrated management using SOLlink
Components
| Robot | The line utilizes Seiko EPSON's LS-b series, a proven product that has held the number one global market share in SCARA robots for 12 consecutive years, and the C series industrial robot.
The LS-b series boasts specifications ranging from a payload of 3 to 20 kg, a repeatability accuracy of ±0.02 mm, and a standard cycle time of 0.4 seconds. EPSON specializes in small robots, focusing on high-speed, high-precision, and low-vibration performance. |
|---|
Workflow
| STEP 1. | The new console parts for SUV-type electric vehicles are largely divided into three parts, each operated on a separate production line. The daily production volume for each line is recorded using the LOT system, with the vehicle type and quantity entered. Based on this data, each product is assigned a number and then production is conducted. |
|---|---|
| STEP 2. | The parts that go into each product are set up on the equipment by the worker, and the part information is linked to the LOT system through a barcode to manage inspection of different parts and missing parts. In normal operation, the robot fastens and assembles the product. |
| STEP 3. | The first line is a flow production line utilizing a conveyor, and the production parts include a wireless charger, a cup holder, and a tray for storing luggage. Due to the nature of the product, it is large in size and the fastening location is at the rear, so it was built as a conveyor type line to simultaneously secure operator operability. |
| STEP 4. | The second line is a standalone modular line, which is the largest part of the console parts, corresponding to the body. Since the assembly section is very small compared to its size, it is a line that is operated as a single unit. |
| STEP 5. | The third line assembles the parts that serve as pillars for the console, which is where the most parts are assembled. Unlike the two products above, this line combines three parts into one instead of assembling one part. Since the assembly time and method for each assembly section vary depending on the vehicle option, the equipment was implemented with a modular concept rather than a conveyor type. As products move through each process, the data is tracked and assembled using LOT barcodes to prevent heterogeneous product assembly. Since there are many product assembly sections, this is the section with the most robots. While other lines only perform vertical fastening, the third line also performs lateral fastening, so it also uses the C series, a multi-joint robot. |
※ The content provided by Bigwave Robotics is protected under U.S. and Canadian copyright and intellectual property laws. Unauthorized reproduction, distribution, or use of this content is strictly prohibited.
Related Use Cases
Automated automotive battery palletizing: Safely stack batteries weighing over 60kg with the YASKAWA GP225 💪
Yaskawa Industrial Robots + Automatic Foam Placement — Hankook & Company Battery Palletizing Automation Case 🔋🤖