Future Trends in Robotics Commercial Vehicle Megatrends India 2012 - PowerPoint PPT Presentation

Future Trends in Robotics Commercial Vehicle Megatrends India 2012 Raj Singh Rathee KUKA Robotics (India) Pvt. Ltd. info@kuka.in www.kuka.in

Introduction Automotive Industry faces right now the largest period of growth in history:  China has already replaced the US as largest automotive market in the world  In the “Rapidly Emerging Markets” the sales volume will be six times larger in 2018  370 Mio. new cars up to 2013  715 Mio. New cars up to 2018  Increasing industrialization and per-capital- income will dramatically increase the car sales volume in general REE’s (Rapidly Emerging Markets): • China • India • Brazil • Russia • Malaysia • Mexico • Indonesia Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 3 www.kuka-robotics.com

Introduction Actual production in India Commercial Vehicles 800,000 700,000 600,000 500,000 400,000 300,000 200,000 100,000 0 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 4 www.kuka-robotics.com

Introduction To meet the requirements of a cost-effective mass- production the automotive industry worldwide will have to develop new body shop and production line concepts:  shorter production lines with higher robot density to minimize the required floor space  shorter cycle time and faster cell-to-cell transport to increase the required through-put  higher availability to guarantee the daily output of the body shop  cost-efficient and multi-functional equipment to reduce the overall investment costs  cost-efficient solutions for standard processes and integration of new processes for light weight bodies  lower life time costs specially in respect to energy consumption Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 5 www.kuka-robotics.com

Content  Compact Production Lines  New Robot Generation for Future Body Shops  Lean and Cost Effective Cell Concepts  Multi-Functional Robot Controller  Energy-Efficient Production Lines  Sustainable and Energy-Efficient Robot Systems  Reduction of Floor Space, Cycle Time and Enhanced Safety  Safe Robot Technology Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 6 www.kuka-robotics.com

 Compact Production  QUANTEC – The New Robot Generation Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 7 www.kuka-robotics.com

Compact Production: QUANTEC - Compact, Fast and Accurate Robots The KUKA QUANTEC Series was especially designed for the future requirements of a compact body shop with highest output and shortest cycle time:  extremely compact design with 25 % less volume  intelligent material selection and latest casting technology  12 % weight reduction  30% reduced energy consumption  minimized interference contours for enhanced accessibility  very small foot print for maximum robot density  reduced weight, highest stiffness of the structural elements and new control algorithms guarantee:  maximum dynamic and speed 25 % faster  highest repeatability ± 0.06 mm  highest path accuracy ± 0.15 mm Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 8 www.kuka-robotics.com

Compact Production: QUANTEC - Minimized Life Cycle Costs The intelligent design and highly reliable components used for the KUKA robot system reduce the operating costs and the maintenance requirements drastically:  up to 30% less energy consumption during production and stand-by  robust and wear free drive chain in axis 3 with straight shafts and without belts  well proven durable SIEMENS motors and sophisticated drive technology  oil change after 20.000 hours of operating time within 30 minutes  exchange of buffer batteries after 4 years  self-explanatory electronic mastering of all six robot axes within 10 minutes  easily accessible mechanical interfaces for wrist exchange within 30 minutes  very fast exchange of media supply without removing the connectors through the 150mm hollow shaft Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 9 www.kuka-robotics.com

Compact Spot Robot – Increasing Robot Density A significant reduction of the production area inside a body-in-white requires an increased robot density that can only be achieved with new robot concepts:  a new generation of extremely compact spot-welding robots with a low overall height  these robots will be installed in front and between standard or shelf-mounted robots  the reduction of the production area leads to:  increased energy-efficiency regarding the building  increased number of process jobs per m 2 and shorter throughput-time  reduction of non-value-adding transportation time  the KUKA CSR family  Reach approx. 1800mm  Height approx. 1300mm  Weight approx. 800kg  Payloads 180kg, 150kg, 120kg, 90kg Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 10 www.kuka-robotics.com

Compact Production: QUANTEC - Productivity Benchmark 7000 Productivity is a measure of the efficiency of a QUANTEC 6000 production process and is measured as a ratio Power Consumption [Wh] Competitor 5000 of output per hour and costs per part: 4000  the energy-efficient design of the KUKA robot 3000 reduces the required energy per production cycle 2000 compared to our competitors significantly 1000  the unmatched speed and acceleration of the KUKA robot allow shorter cycle times without a significant 0 200 400 600 800 1000 1200 1400 1600 Productivity / Cycles per hour increase in power consumption 7 QUANTEC  Reduction of costs per part at the Part Costs / Energy per Part [W] 6 Competitor same production volume 5  Significant increase of production 4 3 volume without effects on the part 15% 2 costs 1 20%  Lower investment costs for a cost-effective production 0 200 400 600 800 1000 1200 1400 1600 Productivity / Cycles per hour Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 11 www.kuka-robotics.com

Compact Production: QUANTEC - Productivity Benchmark Production Benchmark Program Automotive Due to fluctuation in demand the production 3500 volume often has to be adapted to meet the QUANTEC 3000 Power Consumption [Wh] market requirement immediately: Competitor 2500 2000  installing the new KUKA robot system guarantees 1500 shorter cycle times and higher part throughput in QUANTEC PRIME comparison to our competitors + 32% 1000 QUANTEC EXTRA  flexible adaptation of the production volume Competitors + 18% 500 without adding additional robots and almost no adverse effects on the part costs 45 55 65 75 85 95 105 Productivity / Parts per hour  Increased production capacities for the same investment costs  Scalable productivity buffer due to different robot models  Highest volume flexibility to react on market fluctuations Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 12 www.kuka-robotics.com

 Lean and Cost-Effective Production Concepts  Multi-Functional Robot Controller Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 13 www.kuka-robotics.com

KR C4 Controller: Software Replaces Hardware-Components SW-based SW-based Closed Loop Control ProfiNet / ProfiSafe CP1616 ET200S/F DSE SW-based SW-based K1/2 VGA Main Contactor Visualization SW-based SW-based Safety PLC ESC Master-Stack MFC SRDW Future Trends in Robotics KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 14 www.kuka-robotics.com