Robotic Fabricated Weld Line for EV Bus Assembly
Frugalhacks Private Limited, based in India, revolutionized the electric vehicle (EV) bus manufacturing process by implementing a robotic welding fabrication line. This innovative solution addressed several challenges in manual welding, such as inconsistent cycle times, high downtime during changeovers, and lack of modularity in fixtures. By integrating advanced robotics and modular systems, Frugalhacks enhanced production efficiency, reduced costs, and improved safety standards.
- Problem Statement
The existing manual welding process for EV bus variants ranging from 7m to 12m faced multiple issues:
- Inconsistent Cycle Times: Manual operations led to variable cycle times across different bus variants.
- High Downtime: Changeovers between left-hand (LH) and right-hand (RH) panels, as well as roof, front, and rear panels, resulted in significant downtime and alignment issues.
- Lack of Modularity: The absence of modular fixtures increased tooling investments and limited flexibility.
- Manual Handling: Part loading, clamping, and grinding were entirely manual, posing safety and productivity challenges.
- No Real-Time Monitoring: There was a lack of real-time quality validation and process efficiency monitoring.
- Our Solution
Frugalhacks proposed a robotic welded fabrication line designed to address these challenges:
- High Modularity: One fixture group was designed to cover approximately 95% of the 7m, 9m, 10m, X2, and 12m variants.
- Robot Integration: Fanuc M710iC/12L robots were integrated with 6–10m linear tracks and 10/12-axis cubing systems.
- Material Handling: 50m and 30m trunnion conveyor tracks were implemented to handle 5-ton components.
- Zone-wise Fixture Setup: Dedicated fixtures for LH, RH, Roof, Front, Rear, and Sub Assembly were established.
- Infrastructure: The setup included floor grouting on 200mm RCC with a 6m clear height, considering manual loading/unloading.
- Process Support: Siemens PLC/HMI control systems and auto vision systems were employed for position verification.
- Tools & Technologies Used
- Robots: Fanuc M710iC/12L
- Linear Tracks: 6–10m
- Cubing Systems: 10/12-axis
- Conveyor Tracks: 50m & 30m trunnion
- Fixtures: Modular LH/RH/Front/Rear/Roof/Sub
- Control Systems: Siemens PLC/HMI
- Vision Systems: Auto vision for position verification
- Production Parameters
- Daily Output: 10 units per 8 hours
- Cycle Time: 45 minutes per station
- Takt Time: 48 minutes
- Line Efficiency: 85% – 90%
- Weld Parameters
- Speed: 400–500 mm/min
- Wire Feed: 6.5 m/min
- Gas Consumption: 15 Ltr/min
- Current/Voltage: 200 Amps / 20V
- Weld Deposition: 3 Kg/hr
Zone-Wise Equipment Layout
Trunnion System
1-Axis
Conveyor Tracks
65m Skid Conveyor + 20m Cross Conveyor
Linear Tracks
10m, 8m, and 6m
Cubing Systems
10-Axis & 12-Axis
Robot Pedestals
Fanuc M710iC/12L
- Results & Conclusion
- Efficiency Achieved: 45-minute cycle time across 9m to 12m variants using shared fixture positions.
- Cost Optimization: Modular fixtures reduced tooling complexity and cost.
- Flexibility: Layout adaptable up to 15m variant in future phases.
- Operator Safety: Layout accommodates grinding booths and minimizes handling.
- Scalability: Robotic and conveyor systems allow future upgrades in automation and output.
Frugalhacks’ solution ensured repeatable weld quality, high throughput, and reduced operator fatigue, providing a robust fixture foundation for boom and arm production in chain excavators.
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