Sigma has been active in this industry for past few years, from commissioning furnace for baking the engine blocks to converting Siemens S5 to Siemens S7 program for Stamping Press to programming and commissioning Robot Cells.
Automotive industry is a very demanding industry with tight deadlines which requires experience, knowledge, and proper project management to get the job done fast and accurately.
Two robot cells, five Kuka robots, one Siemens PLC, and one Siemens HMI panel.
Our Client wanted to increase the cycle time by adding three new robots (two welding robots and one material handling robot) and remove the bugs in the PLC program which maintenance had hard time to recover from and were causing down time.
At first the three new Kuka robots were configured to communicate with their own I/Os via Profibus, then the new robots were added to the main Profibus network to communicate with the Siemens PLC.
In both robot cell, the sequence in the PLC program was changed to allow two welding robots to work on the same turn table simultaneously in compare to having only one robot working on the turn table.
There were three material handling robots working in the robot cells which were picking up parts from tables and drop them either on nests or conveyor. The robots were going through steps in a sequence for handshaking with the PLC and that was causing issues when a fault was happening or operator has to pick up a part manually because the operator has to reset the sequence and move the robots back to proper position to get them back in the sequence and that was causing down time for the whole line.
We added few more bits for proper handshaking between PLC and robots and replaced the sequences with few simple lines in the PLC code that was independent from where robots were or whether an operator has picked up a part or even has added a part back in the line. A simple change in the PLC code saves lots of hassle from operators and maintenance technicians.