ComauFlex BIW Plant Strategy Xiaowei TAO Manager, GSD Dept, Body Assembly,Comau China Bangkok, June 23rd, 2016
Index Comau General What is ComauFlex Systems & Solutions Products Projects with Aluminium Joint 2
History_Over 40 years of experience in Automotive 1973 Several companies in the Turin area create COnsorzio MAcchine Utensili 1977 Establishment of Comau Industriale with powertrain and body (welding, assemby and handling) divisions 1978 Comau S.p.A. is established incorporating Comau Industriale activities 1995-97 Comau opens plants and offices in Germany, Brazil, Argentina, France and India 1998 Establishment of Comau Service Comau Poland is established 1999 Comau acquires Renault Automation in France and Pico in USA, Mexico, Germany and UK 2000-03 Comau China, Romania and Russia are established 2009 Establishment of Comau Aerospace 2010 Establishment of Comau Adaptive Solutions and ecomau 2013 Comau China in expansion: 3 new sites Kunshan, Shanghai, Dalian 2014 Comau Czech and Turkey are established Comau opens office in Munich (DE) Comau Mexico expansion 2015 Comau Thailand is established Comau São Paulo (BR) is established 3
Comau in the World GERMANY POLAND MEXICO USA UK FRANCE SPAIN ITALY CZECH REPUBLIC ROMANIA RUSSIA TURKEY INDIA CHINA THAILAND BRAZIL ARGENTINA 4 Property of of Comau Comau - Duplication - Duplication prohibited prohibited 4
Business Scope Automotive Commercial vehicles Commercial vehicles Aerospace Heavy industry Energy Defense 5
Key Figures 2012-15 Revenues (MIO ) 1,950 1,450 1,464 1,550 2012 2013 2014 2015 2015 Turnover per area (%) 6
Index Comau General What is ComauFlex Systems & Solutions Products Projects with Aluminium Joint 7
What is A flexible BIW manufacturing strategy Traditional Factory Engineered Factory Logistic Optimized Model change simplify High Speed Transfer Modular Architecture Compact footprint High density welding We deliver the Best Value to our customer 8
ComauFlex Overview Manufacturing Strategy Quality Zone Major Subs & Mainlines Part Loading Zone Marketplace Part Loading & Minor Subs Material Staging Zone Material Entry Zone 9
ComauFlex Overview Direct/Indirect Labor Maintenance Material Handling - Fork-lift - Tugger Production 10
Framing Re-spot Body Side Inner Left Body Side Outer Left Upper Body Framing Body Side Outer Right Body Side Inner Right Underbody Re-spot Front Floor and sub assy Underbody Framing Front Structure and Rear Floor Front and Rear Rails R/L ComauFlex Overview Example VersaRoll VersaPallet ASSEMBLY ZONE MATERIAL ZONE 11
ComauFlex Overview Example Floor Plates BRIC Legs Shipping Modules Integrated Lines 12
How to be ComauFlex Modular Strategy Pallet Tooling VersaRoll OpenGate Pallet Transfers VersaPallet Logistics-SPD Vision Systems AGC Roller Heming Welding Guns Break-Away APC Line Feeding Devices 13
Index Comau General What is ComauFlex Systems & Solutions Products Projects with Aluminium Joint 14
VersaRoll System 15
VersaRoll System For Return All carbinet upstairs Simplify cable/wiring connection Tool tray Space on floor to be extended 16
VersaPallet System 17
VersaPallet System For Return All carbinet upstairs Simplify cable/wiring connection High Desity Robot Welding 18
Opengate System 19
Opengate System Phase 2 Phase 1 Key Features: Up to (18) Welding Robots Integrated solution for cabinets Scalable investment Up to (6) dedicated gates Phase 3 Phase 4 Open RoboGate up to (6) Models Phase 5 Since 2010, 70 stations install in China With 185 gates 20
Index Comau General What is Comau FLEX Systems & Solutions Products Projects with Aluminium Joint 21
Geo Pallet with Power Roller Bed ±0.1mm Repeatability in X/Y/Z NO Air Supply NO Shim Adjustment NO Wiring NO Piping TOLERANCE X ± 0.1mm TOLERANCE Y ± 0.1mm TOLERANCE Z ± 0.0mm(touch) For Geo 6.0s for horizontal transfer 1.5s for pallet up 1.5s for pallet down TOLERANCE X ± 0.5mm TOLERANCE Y ± 0.3mm TOLERANCE Z ± 0.5mm For Respot For Facility 6.0s for horizontal transfer 6.0s for horizontal transfer 22
Compact Gun Family_For Steel Weight 65~90kg + NO casting component Force up to 440 dan Al Alloy Body 7075 + Al Alloy Arm 7075 Common servo motor and transformer Force up to 700 dan 23
Compact Gun Family_For Steel Smaller Robot Less Space Gun Weight 65~90kg More Faster of movement Robot Payload 90~110kg High Desity 24
Market Share (% of pieces) Compact Gun Family_For Aluminium Ducker Worldwide Aluminum in cars, 2015 Aluminum Body and Closure (% of Volume) Compact High Force 2015 Ducker Worldwide Automaker Survey Weight 110 ~ 130 kg MFDC Transformer 255 KVA at 50% DC Welding Force X-Gun 600 dan C-Gun 704 dan Actuator (Inverted roller screw) X-Gun 1764 dan C-Gun 704 dan Software equalizing (COMAU, KUKA, ABB, FANUC) External load washer with amplifier for force feedback 25
Compact Gun Family_For Aluminium Real Applications Test In House Result Achieved: Tip dressing each 24 spots Electrode life up to 2600 spots 26
RecogoniSense System(Vision) RAIO = RecogniSense All-In-One Key Features Recognition process time: < 300 ms Rack position: +/- 75 mm X, Y, Z LED Light +/- 5 R x, R y, R z System Accuracy: +/- 0.5 mm X, Y, Z VOV(Volume of View): Min 50mm x 50mm x 25mm Max 2400mm x 1200mm x 600mm Resolution X/Y/Z: +/- 1.0 mm @ Max VOV +/- 0.1 mm @ Min VOV Resolution Rx/Ry: +/- 0.2 degrees Resolution Rz: +/- 0.1 degrees 3D Camera Processer 27
RecogoniSense System(Vision) Traditional + + + Rack Operator Centering Tooling Robot+Gripper With RAIO + >>>>>>>> NO operator >>>>>>>> NO centering Rack Robot+Gripper+RAIO 28
RecogoniSense System(Vision) Bodyside Outer Loading From normal rack 29
Index Comau General What is ComauFlex Systems & Solutions Products Projects with Aluminium Joint 30
Projects with Aluminium Joint in China Customer Plant Model Scope Production Capacity Joint Technology 1 Jinqiao China O11 Framing Inner;Framing Outer;Sunroof;Respot Line 10JPH RSW/SPR/FDS/Al Laser Brazing/Al Hemming 2 Changshu China X261 UB and UB sub 16.4JPH SPR 3 Hangzhou China CD539 Hood 20JPH SPR 4 South Plant China E15/E16 Hood/Decklid 27JPH Clinch/Al Hemming 5 SGM South Plant China A10 Hood 15JPH Clinch/Al Hemming 31
Projects with Aluminium Joint in China 1 2 3 4 5 SPR FDS 32
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