Automation Integrator Tags Robot Supplier for Big EV Effort

Bulldog Factory Automation has been tailoring factory solutions that improve and make production more efficient since 1937. Initially a small service provider for Detroit-area factories, Bulldog was purchased by HG Automation (HGA) and is now a full-service integrator providing turnkey solutions for body-in-white welding at Detroit’s major OEM automaker and Tier 1 supplier plants. The company maintains a full complement of automation specialists and experts that make it a prominent player in the automotive, heavy-truck and aerospace sectors, delivering custom-made systems from concept to installation.

Recently, HGA’s development and design engineers, automation assembly teams, programmers and installation technicians were all brought to bear when a Tier 1 customer needed a turnkey automation system for a new battery electric vehicle (BEV) component line. HGA was given a condensed timeline in which to design, build, debug, and install a five-zone automation system that incorporated part handling, stud spot welding, and adhesive dispensing for a BEV rear quarter assembly. However, when the customer’s usual robot supplier was stymied by supply-chain issues, HGA turned to KUKA Robotics for help.

“We had been doing small collaborations with KUKA for some time but this was our first large, turnkey automation project that we deployed with them,” recalled Aaron Burke, HGA senior business development director.

In addition to a challenging timeline from design to delivery, the project had to resolve the cost and space requirements. “Essentially, we had to provide a cost-effective, smart solution with the right number of robots and technologies all deployed into package that is as small as possible for our customer,” Burke explained. “Once we got the customer’s specs, we went through a number of iterations, designing and redesigning the process to get a system that could output the right volume of parts.”

That solution was 86 KR Quantec robots from KUKA. The KR Quantec series consists of all-purpose, six-axis robots with payloads of 120-300 kg that allow manufacturers to gain the versatility to handle a variety of production applications reliably. The robots are also very adaptable to cost-effective cell planning, which fit precisely into HGA’s requirements.

“We needed to meet space, volume, and aggressive cycle times, along with other criteria, and KUKA robots allowed us to do that,” according to Andrea Conover, HGA manager of program management, who served as the project manager. “KUKA robots also have great track records of uptime and limited maintenance on the line.”

For the body assembly process, the Quantec robots handle over 30 individual parts and generate more than 300 welds. In complex synchronized movements, they pick parts, transport them to stations where they are welded together, perform a variety of other spot and stud welds, apply adhesives, and unload bodies onto rack stations. In addition to robotics, the system includes technology for trays, conveyors, trunnions, and buffer zones.

Designing and assembling such a complex system was an inherently challenging task that occasionally presented obstacles for the HGA team to overcome. KUKA’s responsiveness was another important element of the project’s success, according to the team.

“While we were debugging the line, we needed support,” Conover said. “KUKA always responded quickly and was onsite immediately to help us out. That support allowed us to maintain our tight time schedule and good relationship with our customer, so everyone’s end goals were met.”

In addition to meeting the system’s performance requirements and KUKA’s support during the implementation process, the ease with which the HGA team was able to program the robots was another notable factor in getting the line up and running on a challenging time schedule. KUKA technology simplified the effort to program the robots for the many precision assembly tasks.

For instance, HGA robot programmer Jared Witt used the KUKA.WorkVisual engineering suite software to program and configure the KR Quantecs, and confirmed that the suite’s overall ease of use during the programming process kept the project on schedule.

KUKA.WorkVisual is a comprehensive tool for configuring, programming, and diagnosing KUKA robots. The suite integrates all steps of the engineering process into a single interface, for a seamless workflow. And it allows users to program and simulate robot motions, test sequences, and optimize performance before deploying robots on the production floor. WorkVisuals’s intuitive design and extensive functionality significantly reduce setup times and improve overall operational efficiency.

Additionally, KUKA.WorkVisual program code is checked for logic in the background as programming steps are being carried out. As a result, errors are caught early on and projects proceed to implementation quickly and consistently.

“This was my first programming experience with KUKA,” Witt recalled. “The WorkVisual along with the company’s KR C5 robot controller helped tremendously in reducing the debug time on the system. I was able to write logic out beforehand and work out all the issues prior to commissioning. Other brands don’t have a program that is as comprehensive.”

Enabling HGA to get its customer’s line into production within the challenging timeline, along with the substantial technical support and technology KUKA provided on the project solidified the two companies’ association for the future.

“This project has been a great experience for us,” Burke said. “KUKA and HGA have developed a solid relationship with one another, and we’ve even started leapfrogging into other areas as a partner in different solutions. That benefits both of our organizations.”

Pjeter Lulgjuraj is the Sales & Marketing Operations Manager, USA for KUKA.