Contactless optical localization of car bodies on welding lines

See how we developed a solution to significantly increase production effectiveness by reducing cycle time and costs associated with vehicle bodies on car production lines.

Challenge

Static robot guidance is commonly used at production lines when welding car bodies at robot workstation cells. The car body must be mechanically lifted and placed in a precise position. The ultimate position of the car body is pre-set using the RPS (Reference Position System) and cannot be changed dynamically. The car body is positioned by lowering the RPS holes in the car chassis over guiding pins. A mechanical clamping device is used to hold the car body in a precise position. The technology is not only demanding for the initial investment but also prone to mechanical damage and increased maintenance costs. In addition, the whole process is not efficient because the vehicle body must be mechanically lifted, which consumes production time.

Solution

DataVision developed a robust contact-less solution for dynamic robot guidance utilizing machine-learning and AI capabilities powered by the BeeYard TM platform. The ultimate requirement was to optimize the process while reducing production costs as well as the risks of mechanical failure.

Dynamic guidance of welding robots means that every time the car body approaches the robot workstation cell, the robots need to adjust their welding paths to the actual location of the car body. This is enabled by a powerful machine learning model that estimates precisely the current position processing data from 2D and 3D images combined with pre-taught position data.

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