Automotive

SENSITIVE ROBOTICS FOR PERFECT AUTOMOBILE MANUFACTURING

FerRobotics augments robots with tactile sensitivity and thus closes quality-relevant automation gaps. Therefore, FerRobotics has been a long-term partner of the automotive industry in a wide variety of manufacturing areas. The reliable FerRobotics products make an innovative contribution to process design in numerous production steps. With the high-quality standards and the high level of automation in the automotive industry, Ferrobotics solutions generate particularly valuable synergies. From body-in-white production to paint preparation, paint repair and final inspection, our solutions set a new industry standard. Active Compliant Technology enables 100% unmanned processing in reliable cycle times and in precisely reproducible top quality.

Typical applications:

  • Grind roof zero joints
  • Grind or brush the door entry way
  • Grind / deburr welding points
  • Grind weld seams
  • Sand filler
  • Spot repair - sanding / polishing paint defects
  • Deburr sheet metal parts
  • Machining aluminum structural parts
  • Sanding wooden interior parts
  • Grind / deburr plastic parts

Grinding,
polishing,
deburring

Roof joint grinding

FerRobotics is creating a new industry standard

With the ASK FerRobotics is creating the new industry standard

The ASK provides fully-automatic grinding of invisible roof joints, brushing of door sills or cleaning of welds. Thanks to the autonomous contact sensitivity, ASK processing attains absolute top quality. The results are so outstanding that manual reworking is no longer necessary. The ASK was developed to close automation gaps in bodyshell work.

Fully automated spot repair on clear coat

The elimination of defects on the clear coat is crucial for the final paintwork. In combination with an automated detection system and the Active Orbital Kit it is possible to fully automate this delicate manual process. The AOK/XS provides the essential active force control and sensitivity and therefore not only delivers a perfect paintwork quality, but also achieves substantial cost savings.

Automated polishing with UR cobots and the FerRobotics sanding kit

Using the AOK905 for the automation of sanding or polishing processes with a collaborative robot is not much effort. Fast and easy to programm, this combination achieves perfect polishing results in constant high quality. The AOK905 autonomously compensates surfaces tolerances with consistent contact force.

Automated polishing of carbon parts

The automated polishing of parts with complex surfaces, such as a carbon hood in this case, becomes efficient only through the use of the Active Compliant Technology. Active compensation of tolerances, immediate adaptation to complex shapes and an always constant contact pressure result in a high quality and faster cycle times.

Fully automated power-controlled brushing of welding spatters

The ASK Brush as a process-optimized end-of-arm comfort solution contains important peripherals such as servo technology, electronics and extraction. It controls all process parameters individually but coordinated with each other. The ASK Brush brushes guns and welding spatters without damaging the galvanized surface and removes residues.

Fully automated surface preparation for paint finish

The AOK delivers a perfect surface preparation for the finishing in just a few steps. In 24/7 use it removes sharp edges and burrs from the workpiece quickly and efficiently, without changing its geometrical form. No need of rework. Providing active compliant force control, the extraordinary durable orbital grinder generates a uniform, reproducible surface appearance.

Force-dosed automated weld leveling

Due to the exactly constant contact pressure and the resulting constant removal of a protruding weld seam, a perfect and exactly reproducible result is achieved. With this industrial angle grinder with integrated force control, all process parameters such as rotation speed, contact force and feed rate can be adjusted individually. The excellent abrasion performance in 24/7 operation requires no rework.

Grinding the exhaust pipe of car with the ABG

The ABG is the perfect tool for grinding stainless steel surfaces. Ideal for small and medium sized workpieces, the ABG achieves identical reproducible surface quality and a high production output through fully automated grinding. The results are reliable cycle times and there is no rework necessary.

Rapid contacting of surfaces subjects

This polishing process demonstrates that with the ACF surfaces can be contacted rapidly and reliably. Special functions prevent the formation of grinding marks. This significantly shortens cycle times and the process becomes precisely reproducible and seamlessly controllable. Uniform 24/7 processing ensures a constant level of quality.

Automatic grinding of overhangs

The Active Compliant Technology from FerRobotics removes material overhangs fully automatically. The technology is characterized by automatic tolerance compensation and exact force control. As a result, undesirable material overhangs are inspected and removed with precision.

Automated deburring of injection molding parts

The ACF from FerRobotics is the velvet glove whose precise force control guarantees perfect results. With the automated processing , precise cycle times, productivity gains, as well as higher quality are achieved at lower costs. This innovative technology from FerRobotics brings this manual task to an automated top standard.

Industrial sanding process of car attachment parts

Due to its sensitivity, the ACF is the ideal equipment for the automated processing of plastic parts. Thanks to autonomous contact sensitivity, ACF processing attains absolutely top quality. The results are so outstanding that manual reworking is no longer necessary.

Automatic removal of weld spatter

The proper brushing process can only be guaranteed by the Active Compliant Technology. The AOK automates this application easily and is therefore already successfully installed in many car factories all over the world. High-grade steel alloys are galvanic coated and shouldn't be damaged due to corrosion risk in no case .

Perfect paintwork quality

Perfect paintwork quality can only be achieved with a perfect grinding process prior to the top coat. Through automation of this grinding procedure, the luster of the paintwork is significantly improved. As FerRobotics is for both, body filler grinding and spot repair, the leading solution provider, car manufacturers all over the world use this high-quality grinding technology.

Automated grinding of thin-walled workpieces

With the ACF it is possible to reproduce lower forces (3 - 8 N) constantly 24/7. This force control prevents grinding through of thin-walled or soft workpieces, like they are used in high-quality car seats. This very thin layer of breathable coconut fibers which is integrated in car seats needs to be processed very carefully.

Grinding of door welding seam

Due to the interactive compensation and guaranteed consistent contact force of the ACF, tolerances in surfaces can be balanced automatically and thus reproducible high quality can be achieved. The automation of the grinding process not only results in 100% savings in problematic manual work but also in significant reductions in abrasive consumption.

Fully automated polishing of challenging outlines

Despite many recesses the AOK polishes the complex surface of a motorcycle part with high speed. The contact-sensitive Active Orbital Kit is worldwide the only end-of-arm comfort solution for fully automated polishing. The AOK is suitable for highest quality requirements regarding shapes, materials or for delicate workpieces.

Automated car wing polishing

With the AOK905 polishing and sanding processes can be automated easily. The package solution consisting of an orbital sander and the Active Compliant Technology is a Plug’n’Play solution that delivers high-quality results even for complex shaped parts. The outstanding benefits of the system are the automatic tolerance compensation and precise consistent contact force.

Automated sandpaper changing station for finesse sanding

For a fully automated sanding process not only the robot suitable orbital sander is essential but also the equipment it comes with on order. The delivered abrasive changing station includes a paper removing tool and a paper magazine with internal process control. The changing station can be used for our AOK XS with adhesive papers daisy shape.

Automated deburring with ACF-Kit - Die Grinder

The ACF-Kit with its large selection of tools covers an extremely wide range of applications. The versatile and user-friendly plug & play tools are suitable for surface processing of almost all shapes and materials. Needless to say that tool change is ingeniously simple and flexible.

Automated sandpaper changing station for AOKXS

For a fully automated sanding process not only the robot suitable orbital sander is essential but also the equipment it comes with on order. This changing station can be used for our AOK XS with hook and loop sandpapers daisy shape.

Automated deburring with the cobot surface treatment solution ACF-Kit - Small Angle Grinder

Using the, especially for cobots developed, ACF-Kit deburring is as easy as it gets. The patented Active Compliant Technology ensures adjustable contact force and automatic tolerance compensation and therefore guarantees optimal quality. Thanks to the modular structure, the user-friendly Plug & Play tools can be changed within seconds.

Automated sand paper changing station

For a fully automated sanding process not only the robot suitable orbital sander is essential but also the equipment it comes with on order. The delivered abrasive changing station includes a paper removing tool and a paper magazine with internal process control. The package is designed for industrial use, 24 hours a day, 7 days a week.

Scan and polish with CraftMate software and ACF-Kit - Orbital Sander

The combination of CraftMate and ACF-Kit achieves best effects possible: easy path creation, exact force control, autonomous tolerance compensation and high precision. The ACF-Kit with its large selection of tools was especially developed for cobots to automate surface treatments of small to middle lot sizes.

Sanding with the ACF-Kit - Die Grinder
The ACF-Kit is presumably the simplest and most flexible Cobot tool on the market for small and medium-sized companies. Equipped with the Active Compliant Technology the ACF-K automates even small batch sizes with minimal programming effort and almost no set-up time. Modular built, the kit has been designed for surface processing of different shapes and materials.

Joining,
adhering,
mounting

Car door sealing

Due to Active Compliant Technology Precisely reproducible

Force-controlled gluing of door seals

In an automated process, the ACF guarantees the required pressing pressure for a perfect gluing of seals on vehicle doors. Also radii are handled easily. The reliable process security of the automated gluing process eliminates the problem of possible water ingress and guarantees a consistently high quality standard.

Joining with integrated quality control

The ACF offers force control for both, pushing and pulling. That is why this equipment is the ideal automation solution for inserting plugs on car bodies. At the same time the firm fit of the plug is checked and all joining parameters are transmitted by the ACF to the control system. Each work step is documented precisely, enabling quality control to be carried out continuously and fully automatic.

Handling

Stack glass and ceramics

Rapid and intuitive stacking of critical workpieces

Rapid and intuitive stacking of critical workpieces

Thanks to the sensitive ACT, it is possible to quickly grip critical parts such as e.g. glass or ceramics and rapidly and sensitively touch defined stacking heights. The placement process is significantly facilitated through the functional sensitivity. The process creation occurs easily and quickly without complicated calculations.

 

Quality
control

Car door gap measurement

Fully-automatic gap measurement of moving parts

Fully-automatic gap measurement of moving parts

The ACF creates the necessary conditions to enable an automatic measurement by means of a laser sensor. To automatically measure the gap dimension between body and door, even in case of design-based differences, the door must be adaptively and precisely closed with a defined force. In the following step, the gap dimension is measured by a laser. The information gathered is then sent to the next processing station.

Automated ultrasound measurement with constant contact

The ACF ensures constant contact between the ultrasound head and the workpiece. Independent of the workpiece shape, the ACF follows the surface curvature with the desired contact force.

Cobot
applications

Car wing polishing

Scan and polish with CraftMate and ACF-Kit

Scan and polish with CraftMate software and ACF-Kit - Orbital Sander

The combination of CraftMate and ACF-Kit achieves best effects possible: easy path creation, exact force control, autonomous tolerance compensation and high precision. The ACF-Kit with its large selection of tools was especially developed for cobots to automate the surface treatment of small to middle lot sizes.

Automated deburring with ACF-Kit - Die Grinder

The ACF-Kit with its large selection of tools covers an extremely wide range of applications. The versatile and user-friendly plug & play tools are suitable for surface processing of almost all shapes and materials. Needless to say that the tool change is ingeniously simple and flexible.

Automated car wing polishing

With the AOK polishing and sanding processes can be automated easily. The package solution, consisting of an orbital sander and the Active Compliant Technology, is a Plug’n’Play solution that delivers high-quality results even for complex shaped parts. The system brings the crucial head start through automatic tolerance compensation, precise consistent contact force and low motor currents.

Automated polishing
Using the AOK905 for the automation of sanding or polishing processes is not a big effort. Fast and easy to program, the combination cobot and AOK achieves perfect polishing results in a constant high quality. The AOK905 autonomously compensates surfaces tolerances with consistent contact force.
Force-controlled gluing of door seals

In an automated process, the ACF guarantees the required pressing pressure for the perfect gluing of seals on vehicle doors. Also radii are handled easily. The reliable process security of the automated gluing process eliminates the problem of possible water ingress and guarantees a consistently high quality standard.

Contact-sensitive processing of carbon parts

The sensitive Active Compliant Technology follows the surface contour and independently levels the process-dependent tolerances. It produces the surface finish that is required for further processing and achieves the highest level of quality. Products made of carbon can thus be processed easily, reliably and automatically.

Automated deburring with the ACF-Kit - Small Angle Grinder

Using the, especially for cobots developed, ACF-Kit, deburring is as easy as it gets. The patented Active Compliant Technology ensures adjustable contact force and automatic tolerance compensation and therefore guarantees optimal quality. Thanks to the modular structure, the user-friendly Plug & Play tools can be changed within seconds.

Sanding with the ACF-Kit - Die Grinder
The ACF-Kit is presumably the simplest and most flexible cobot tool on the market for small and medium-sized companies. Equipped with the Active Compliant Technology the ACF-K automates even small batch sizes with minimal programming effort and almost no set-up time. Modular built, the Kit has been designed for surface processing of different shapes and materials.

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Room for Improvement

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