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Industrial robots are advanced machines that can be controlled and programmed to fulfill repetitive tasks requiring consistency. Thanks to their programming, these robots can minimize (or eliminate) the need for human intervention, especially when it comes to completing hazardous or repetitive tasks. They consist of five key parts:
Industrial robots commonly take the shape of an arm, which can mimic human movements.
Vehicle manufacturing demands precision and consistency. Over the years, automotive manufacturers have relied on industrial robots to ensure this precision and consistency across various applications in the production process, such as:
Robotic arms are used extensively for spot welding and arc welding for cars. Their high precision, consistency, and speed in dangerous environments make them ideal for ensuring consistent structural integrity. Additionally, smaller robots can weld subassemblies to reduce the risk for humans and prevent injuries.
Robots can apply consistent amounts of paint with a consistent degree of pressure, which reduces waste. On top of that, painting robots protect human workers from exposure to harmful chemicals.
From start to finish, the assembly line is often full of industrial robot arms. The robotic assembly line allows tasks such as screw driving, windshield installation, and wheel mounting to be handled with ease.
Small robots, or Delta robots, are particularly well equipped to handle complex and intricate tasks, such as assembling motors and pumps.
Industrial robots are equipped with advanced vision systems that allow them to conduct automotive quality inspection tasks. The technologies ensure consistent quality across the board for all cars in the production line.
There are also lower-cost Collaborative robots that work alongside human workers, handling parts that may be sharp or dangerous.
Robotic arms can also move heavy car parts, speeding up the automotive supply chain and reducing risk for human workers.
Robots can produce airtight and watertight seals by applying sealants and adhesives to door frames and windshields.
Because they can be pre-programmed, automotive manufacturing robots can perform a crucial step in the production process: cutting and milling.
By using robots, cutting materials and machining engine parts can be conducted with greater accuracy.
Robotic arms can load and unload parts from other machines, such as CNC machines and presses, to speed up the workflow and reduce cycle times.
The final stage of the manufacturing process is packaging and palletizing parts. The use of robotics allows for more organized and efficient packing, minimizing the amount of space being used.
Robotic assembly is used by some of the biggest names in the automotive industry. From collaborative robot-powered automation to completely automated assembly lines, these are some companies making use of robotic systems:
General Motors is best known for producing Chevrolet, Cadillac, GMC, and Buick vehicles. They currently use exoskeletons for repetitive tasks. This helps keep workers employed while making the manual labor processes easier on their bodies.
One of the most advanced production lines in automotive manufacturing belongs to Tesla. The electric car brand is home to a machine that stamps 13 different body parts with 73,000 tons of force, all in a press line that runs up to 16 parts a minute.
As one of the giants in this sector, Toyota does a good job of keeping on top of car manufacturing trends. The robots used in their car manufacturing process focus primarily on welding, painting, and assembly.
Known for its exclusive and expensive hypercars, Koenigsegg also makes use of robotic systems to produce cars that have one-of-a-kind speed dynamics and designs. Specifically, Koenigsegg uses 3D printing for both the manufacturing and design stages of its One:1 sports vehicle.
The automotive industry benefits greatly from using robots in the car manufacturing process. However, it's also important to take a look at the manufacturers of the machines themselves.
FANUC America is the world's leading supplier of industrial robots for the automotive industry. Notable names include BMW, Volkswagen, and Audi.
Rockwell Automation offers different technologies to help companies scale their car manufacturing process. What makes them stand out is that they work exclusively with electric car manufacturers.
ABB offers robots that work independently without human intervention. Their machines are designed for the final assembly process and can paint, press, and frame cars. They're currently looking at developing solutions for battery, e-motor, and interior assemblies.
The use of robots when assembling vehicles can speed up the production process, ensure consistent quality, and maintain acceptable standards.
No, robots will not replace humans. While robots can handle multiple tasks efficiently, they still require human oversight and programming.
As of March 2023, there are around 1 million robots being used in the automotive industry.
The automotive industry has always been at the forefront of design and production. The use of robotics to speed up this process has helped to push the car manufacturing industry to new heights and is the reason we have some of the most beautiful (and fastest) cars today.