Client Needs & Project Goals

An automotive supplier required a semi-automated solution to assemble three specific components onto vehicle fenders: a blue plug, a white plug, and a Riblock clip.

Key requirements included:

  • Reliable and repeatable mechanical assembly of multiple components,
  • Integration of two robotic systems for parallel assembly processes,
  • Automated verification of component presence through visual inspection,
  • Tracing and marking of correctly assembled parts,
  • Ability to manually correct missing components without halting production.

The aim was to enhance process efficiency, minimize operator errors, and ensure full quality control in high-volume production.

Project Implementation & Technical Breakdown

The system integrates multiple technologies including robotics, pneumatics, visual systems, and dosing mechanisms. The process is structured as follows:

1. Workpiece Loading

  • The operator manually inserts the fender into a dedicated fixture.
  • Pneumatic clamping cylinders rotate and lock the part in place.

2. Position Verification

  • Sensors verify that the part is fully seated.
  • Once confirmed, a rotary table rotates the fender into the assembly position.

3. Automated Assembly

  • An ABB 6-axis robot picks blue and white plugs from vibratory bowls and inserts them into designated positions.
  • Simultaneously, an Epson SCARA robot places Riblock clips, fed via a flexible hose from a separate feeder.

4. Visual Inspection

  • After assembly, the rotary table returns to the loading position.
  • Vision system checks for the presence of all components.

5. Marking and Unlocking

  • If all components are present, a needle-actuated cylinder marks the part.
  • The part is unlocked and removed; the cycle is ready to repeat.

6. Manual Correction (if needed)

  • If any component is missing, the system prompts the operator for manual insertion.
  • Visual inspection is automatically repeated before proceeding.

Results & Benefits

With this solution, the client achieved:

  • Reduced operator error through automation of critical steps,
  • Faster cycle times via dual-robot parallel processing,
  • 100% in-line quality control through vision inspection,
  • Manual correction possible without production interruption,
  • Increased traceability through mechanical part marking.

Summary

  • Semi-automated multi-component assembly
  • Dual robotic cell with synchronized operation
  • In-line vision inspection for zero-defect control
  • Built-in traceability and rework support
  • Higher throughput and process reliability
Station for Automotive Fender Components bird-eye
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Thomas Magnete

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