As customer requirements for
bodyshop flexibility increase, another problem arises: how can sub-assemblies, or even a complete
car body, be moved across the production line without restricting
flexibility?
At present, conveyors use model-specific pallets or tooling to handle the parts during motion. These pallets have to be returned to the beginning of the conveyor system when empty. This return circuit is cumbersome, often requiring an aerial system located on a mezzanine. This makes it expensive. Moreover, the co-existence of several car models in production means several pallet types exist, each requiring different treatment.
Under such conditions, dealing with more than two car models in the same line becomes a logistical nightmare. Once again, the solution lies in flexible tooling using three-axis robots to position the part locators. This programmable jig is carried by a linear track motion, which like the robots, is driven by the IRC5 controller. FlexTrack was developed for applications where compactness, protection and cost efficiency are required. The compact width allows optimized layouts where the stationary FlexPLPs are close to the linear track. All internal guidance and transmission components are protected against pollution from welding. This linear track motion can also be used to carry robots for various processes such as gluing and palletizing. An additional strength of such a linear track motion system as compared to a conventional conveyor system is that each car body is moved individually with a very high accuracy and repeatability. This can greatly simplify certain steps. The transfer time is drastically reduced to less than 5 sec for 6 meters.
FlexTrack is available in four versions (IRT 501-66, 501-66R, IRT 501-90 and IRT 501-90R), offering various payload and width.