Efficient automation

for the Automotive

Industry

Assembly Speed and flexibility PAGES 20–27

Meet the world’s first robot for your powertrain production processes
capable of lifting an entire
car – and the world’s strongest
collaborative robot with its
35 kg payload.
Small parts and pre-assembly PAGES 10–13

PAGES 32–35
Better body shop PAGES 18–19
 AUTOMOTIVE INDUSTRY 02 | 03

Revolutionising efficiency
through automation
Since the early sixties when robots first took their place on factory floors, factory automation systems
have been revolutionising the automotive industry. Today, robots and CNC machines are installed in
car and automotive component plants around the world. Contributing massively to manufacturing

 Fast integration and setup

efficiencies, these ensure manufacturers and suppliers alike to keep costs low and stay competitive.
But this revolutionary process is still only just at the beginning. Heralded by the Internet of Things,
To make setting up as quick and easy as possible, many FANUC solutions incorporate future-proof
the future will see fully networked smart factories operating at incredible high levels of efficiency and
plug-and-play technology that is smart factory ready. These out-of-the-box technologies effectively
making a huge impact on the value chain. For the automotive industry, these solutions will be built eliminate downtime and enable you to create your own solutions using simple menus.
around modularity, seamless communication and interfaces, energy efficiency, space savings and,
in order to open up new realms of opportunity, human-machine collaboration.

One common platform, multiple solutions

For almost 40 years, FANUC has been part over 2000 robots manufacture a vast range FANUC’s unrivalled one common platform approach enables the seamless integration of

 uilt around
B of this story, partnering with OEMs and au- of automation solutions. At the time of go- intelligent solutions and reduces the need for additional i­nterfaces­and wiring to a bare minimum.
tomotive suppliers to increase productivity ing to print, some 380,000 FANUC robots,
the Japanese and add value to supply chains throughout
the industry. Now as before, FANUC’s man-
3,300,000 CNCs and 256,000 machines were
in operation in automotive plants around
principles ufacturing philosophy has also been help-
ing to drive this revolutionary change. Built
the world. FANUC reliability ensures that
every one of these machines boasts an ex-
of efficiency, around the Japanese principles of efficien- tremely low mean time between failures.

simplicity and
cy, simplicity and reliability, it encapsulates
all the principles that underpin tomorrow’s
Delivering the lowest possible TCO on the
market, all FANUC products combine low
Maximising energy efficiency
All FANUC products are designed with maximum energy efficiency in mind.
reliability smart automotive factories. Nowhere else
on earth can this be seen better than in
running costs with flexibility and consist-
ently high rates of throughput.
Incorporating smart energy-saving features and intelligent servo technology,
they provide maximum output for the lowest possible energy consumption.
FANUC’s own production facilities where

Minimising floor space requirements

Since factory floor space is at a ­premium,­FANUC products are built to make best use of it.
Solutions include slim robots that come with a range of versatile mounting options, compact
machining centres that outperform larger machines­and intelligent DCS software that allows you
to clearly define robot work areas according to designated safety zones.
 AUTOMOTIVE INDUSTRY 04 | 05

20 | 27
Added value
all along the automotive value chain from Tier 5 to OEM
Powertrain
Speed and flexibility for your powertrain production, complex machining, cylinder head & cylinder block,
gear & transmission cutting, non-cylindrical crankshaft machining

06 | 09
22 | 23 Drilling Milling EDM
Oil and transmission pumps, FANUC cutting philosophy, integrating a transfer line into a single
machining centre, production cells for connection rods, transporting workpieces between machines

Handling, loading, unloading 24 | 27 High-quality CNC applications

Transport, depalletising, line charging, Hard turning, high-quality surface finish
bin picking, handling heavy parts

14 | 17
Press shop
Efficient metal sheet handling,
press tending, energy-saving
cutting technology, the perfect
CNC for presses, large motors

10 | 13
Small parts manufacturing and pre-assembly
Adaptable injection moulding for a multitude of parts, flexible line transfers for
smaller charges, flexible ARC welding solutions, high-speed pre-assembly
28 | 29
If it can’t do
everything, does

18 | 19
having a robot
add up?
An interview with
Body shop Markus Frischeisen,
Low-cost automated spot welding, coordinated motion, faster welding Head of Automation
Development at AUDI AG
32 | 35
times, laser welding, the fastest welding cell in the world

30 | 31
Paint shop
Painting, finishing, underbody sealing,
Assembly
Body transfer, handling complete cars 36 | 39
without lifting systems or cranes,
specific FANUC paint series new possibilities thanks to collaborations Support & service

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Intelligent front-of-line
operations for more productivity
Efficient manufacturing starts with front-of-line processes such as transporting parts to production
lines, depalletising, loading and line charging. Given changing production runs and a huge diversity
of components, automated solutions need to be fully customisable as well as supremely adaptable
and need to incorporate smart system solutions that reduce cycle times and drive productivity. The
most effective way to achieve this is to choose a system capable of coordinating different robots and
transfer lines using one common control. Not only does this drastically reduce integration time but it
also saves valuable floor space and money since the need for additional interfaces and wiring is kept
to an absolute minimum.

Automated bin picking for

powertrain or body shop
Originally conceived for the Japanese market where labour costs are
extremely high, FANUC’s 3D Area Sensor combined with a handling
robot provides non-stop unmanned unloading capabilities, even in
Heavy parts handling – featuring high-performance capabilities and payload capacities up to 2300 kg, the FANUC range of
situations involving dirty, dusty or rusty products and/or difficult light industrial robots makes light work of even the most demanding of front-of-line material handling operations.
conditions.

Easy to set up and program, it provides flexibility and increased efficiency

on a range of front-of-line operations such as bin picking powertrain The CNC for motion applications
castings for deburring or body parts for assembly. Completely integrated
into the robot controller, FANUC’s high-speed 3D Area Sensor uses Ideally suited to transfer and front-of-line material handling operations, a single FANUC Power Motion i-A CNC will control
structured light projection to create 3D maps. Using these maps, the several robots on a single or on multiple lines. Faster and offering you more options than a conventional PLC solution, one
system looks for parts. The part manager then does an evaluation control will synchronise up to 32 axes.
and decides which part to pick. Taking reaching distance and collision
avoidance into account, it then chooses the fastest picking option. If the FANUC’s Power Motion i-A has been designed for a wide range of complex, high-performance general motion applications involving
part manager decides a pick has been unsuccessful or a part queue does multiple axes, paths, speeds and torque controls. The biggest benefit: Power Motion i-A includes all the features of FANUC CNC technology.
not contain a part to pick, another image is taken and the process starts Often faster and offering more options than conventional solutions, when used in conjunction with rack-mounted robots, one Power
again using the new results. Motion i-A control will manage every loading, unloading, picking and placing process on your line. And since it’s expandable, it allows you
Fitted to a gantry above the bin, FANUC 3D to keep adding further equipment such as conveyors to your system. What better way of future-proofing your business?
Area Sensor tells the robot which part to pick.


High-speed heavy parts handling FANUC smart tip

Featuring high-performance capabilities and payload Save energy on your production lines by using smaller
capacities up to 2300 kg, the FANUC range of industrial robots. You will be surprised at what they can do.
robots makes light work of even the most demanding of
front-of-line material handling operations.
Discover the entire range of FANUC handling robots
www.fanuc.eu/handling

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LISI AUTOMOTIVE
Saint-Florent-sur-Cher, France

Coordinated tending
robots drive productivity
LISI Automotive France, a manufacturer of automotive safety
equipment with a 200-year industrial heritage, has doubled capacity
and improved quality on its machining lines by integrating FANUC
robots into the setup.

The completely unmanned solution employs a rail-mounted M-20iA robot to distribute

parts between the machining stations. At the stations another eight smaller LR Mate 200iC
robots tend the machines and carry out quality control checks using visual intelligence.

The robots are coordinated by a single FANUC CNC which constantly communicates with
them, adapts to their needs in real time and, if necessary, reschedules tasks to maximise
efficiency. The system’s Dual Check Safety (DCS) feature enables operators to enter the cell
safely without interrupting production. When an operator enters the cell, the M-20iA simply
revises its priorities and moves away from the operator while continuing to work. As well as
increasing efficiency, the system has improved quality. The extra capacity gained by adding
the robots has also enabled LISI to focus on new markets and grow its business.
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Adaptable injection moulding

for a multitude of parts Thomas Hähn
Owner and MD of Hahn Automation, Rheinböllen, Germany
Modern vehicles contain a wealth of injection-moulded parts
ranging from instrument panel components and lenses that
demand extremely high levels of quality through to items such
as interior trim, fastenings and electrical connectors. In order to “TO STREAMLINE INJECTION MOULDING PROCESSES, OUR MASTERSHOT
produce these parts as efficiently as possible, manufacturers need
PLASTICS CELL IS CONTROLLED BY A FANUC 31i-B CONTROL TO RUN
machines to be capable of supporting a wide range of processes
and maintaining extremely high quality standards. To minimise
THE CELL AND EQUIPPED WITH A FANUC CNC POWER MOTION i-A TO
production time, machines also need to offer extremely high 
MANAGE THE THREE-AXIS REMOVAL DEVICE.
THE RESULT IS AN IDEAL
levels of reliability and fast turnaround times. FANUC smart tip COMBINATION SINCE BOTH CONTROLS COME FROM A SINGLE SOURCE
WHICH MEANS THERE ARE NO WORKAROUNDS REQUIRED DURING
Automotive parts frequently
require cores. For these kinds of INTEGRATION. THIS MAKES THE HAHN AUTOMATION MASTERSHOT
applications, FANUC ROBOSHOT USER-FRIENDLY FOR OPERATING PERSONNEL AND MAINTENANCE
is also available with hydraulic and
fully CNC-controlled servo cores. TECHNICIANS.”

Save energy on the shop

floor as well as the road Relentless
Plastic automotive parts do not repeatability
only equate with lighter energy-
saving vehicles. Since they are Producing high-quality plastic parts for
quick and easy to produce using the automotive industry requires that
the world’s most energy-efficient suppliers ensure incredibly high levels
injection moulding machine, the of repeatability throughout very long
real savings start on the factory production runs.
floor.
Here ROBOSHOT is in a class of its own –
Superior servo technology and with every machine delivering exactly
­intelligent energetic recovery the same quality after 50,000 cycles Tending robots for part removal, screw cutting, degating,
One common control platform for easy robot integration.
labelling, lasering and adding inserts.
­reduce FANUC ROBOSHOTs' as it did on the first shot. The most
energy consumption by 50–70% reliable machine on the market, it will
compared to hydraulic machines also keep on producing flawless parts
and by up to 10–15% compared to over the long term, delivering excellent
other manufacturers’ electrical cycle times and requiring minimum
machines. Given very low main- maintenance.
tenance costs, very high levels of For full transparency and superior Flawless parts every time thanks
uptime, fewer components and to maximum repeatability.
quality management, ROBOSHOT comes
less wear, ROBOSHOT provides the with up to 16 Multi Cavity Pressure
lowest Total Cost of Ownership on Channels, cavity balance monitoring and external components, monitoring is
the market. historical data collection. To save money, done via the CNC. You just select the years of
ensure easier operation and minimise required part quality.
ROBOSHOT FANUC ROBOSHOT α-1000iA
technology www.fanuc.eu/uk/en/roboshot
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Solutions for faster pre-assembly

Pre-assembly can involve a myriad of parts and processes and impact almost every tier in the supply
chain. To make these key processes more efficient, FANUC has developed a range of intelligent Peter Hoedemakers
solutions designed to streamline processes such as seat and light assembly, large component welding Production Engineer at DAF
and much more. FANUC’s extensive range of automotive welding solutions, for instance, benefits
from compact design, extremely fast motors and excellent acceleration. Every model helps increase
weld quality, lowers your manufacturing costs and improves cycle times.
“THE CELL WORKS REALLY WELL AND IS VERY FANUC M-1iA ROBOT
EASY TO USE. OPERATORS SIMPLY PUT A NEW DISPENSES GLUE
BIN IN THE CELL, SCAN THE LABEL AND PRESS ONTO PART AND
Flexible adaptation ‘START’.” VERIFIES USING
to every assembly Leading truck manufacturer DAF uses FANUC robots in pre-machining
ERROR PROOFING
situation operations for con rods at production sites in the Netherlands. The FANUC
R-2000iB robot uses FANUC iRVision to identify and pick con rods from a bin,
The robot uses iRVision Multi-
View to locate the part, after
orientate and place them into a laser machine ready for data matrix coding
Available with different reaches and which it employs the vision
and verification. The con rod is then placed on a conveyor for grinding and
wrist speeds, FANUC’s human-arm- offsets to adjust the dispensing
onward processing. The FANUC project was launched to improve ergonomics
sized LR Mate robots are your best path. During the dispensing
and reduce costs. Compared with manual picking, an automated solution
compact solution for fast handling process, iRVision error proofing
makes for a more ergonomic environment and allows for data matrix coding
and processing parts up to 7 kg with verifies that the glue is present
onsite rather than on external suppliers’ premises. Ergonomic and cost
a calculated TCP speed of and has been dispensed evenly
benefits include reduced manual labour – one con rod weighs 5 kg, and an
max. 4000 mm/sec. onto the part.
average 500 are handled every shift. Onsite data matrix coding reduces costs
and use of raw materials.
This compact multi-function robot
offers you full flexibility thanks to floor,
ceiling, wall and angle mounting. With its
compact design and sealed mechanical
units (IP67), you can even integrate it
directly into your machine tool. Its unique
flip-over capability is the solution for
reduced cycle times, more flexible cell 
designs, a full work envelope in upside- Coordinated motion FANUC smart tip
down mounting and the ability to run
LR Mate equipped with a Force Sensor and vision system carries out a deburring operation. several robots close together. To reduce setup times on complex welding operations For advanced welding applications, FANUC offers 1- and
involving multiple robots, FANUC constant path 2-axis positioners in a range of payloads up to 1500 kg for
functionality makes teaching complex motion paths coordinated arc welding.
much quicker and easier.

Automated seat welding

Specifically designed for arc welding applications, the FANUC ARC Mate 0iA robots
are extremely lightweight and compact. Equipped with FANUC iRVision, a FANUC ARC
Mate 100iC robot picks parts from a tray and sets them into an automotive seat fixture.
The ARC Mate 0iA and the ARC Mate 100iC robots then perform a spatterless welding
operation. Once the weld cycle is finished, the ARC Mate 100iC unloads parts while the
ARC Mate 0iA performs additional welds, and the cycle repeats.

Discover the complete FANUC pre-assembly range

www.fanuc.eu/assembly
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Adaptable repeatability
for your press shop
Stefano Fava
Pressing and fabricating automotive body panels involves the precision control of very high-exertive General Manager at Starmatik, Treviso, Italy
forces to accurately form sophisticated geometries. Presses not only need to provide repeatability
but also a high level of adaptability given today’s shorter product life cycles and frequent model
changes. The key to maximising the efficiency of these systems lies in the control and drives, and
how well they interact with the distributed I/O, operator control and monitoring systems. Having one
common control capable of coordinating an entire press or fabrication cell, including presses, cutting
equipment and tending robots reduces complexity and makes adapting to new production scenarios
easy. Opening up your options, advanced FANUC CNC technology provides you with the power to
make the most of your metal forming processes. Whether it is bending, roll forming, spinning, deep
drawing or stretch forming, reshaping sheet metal is more efficient with a FANUC CNC.

Efficient sheet metal handling

High-speed robots equipped with generous work envelopes are ideally suited to
maximising the efficiency of sheet metal handling operations. In more challenging FBS – FLEXIBLE BENDING SYSTEM. Fully automatic bending cell composed of FANUC R-1000iA/100F robot gantry with 7th axis,
situations this can be improved further with the help of coordinated motion complete with job list management, automatic gripper change, tool change, metal sheet preloading system, optical vision system for
functionality. detection of stapled sheets.

Coordinated motion technology enables robots to work together, holding or

manipulating workpieces for one another as well as providing exact work and travel
“AN AUTOMATED BENDING SYSTEM OFFERS SEVERAL ADVANTAGES,
angles. With more than 100 models to choose from, FANUC offers the widest range AND NOT JUST IN TERMS OF PRODUCTION SPEED AND EFFICIENCY.
of robots in the world. Ideally suited to sheet metal, vehicle shell and panel handling
applications, FANUC robots are easy to teach and offer huge amounts of flexibility
USING ROBOTS FOR THIS KIND OF PROCESSING SIGNIFICANTLY
A FANUC R-2000 equipped with a
gripper carries out a handling operation.
thanks to a range of application-specific options, straightforward integration, REDUCES THE RISK OF OPERATOR INJURIES AND OCCUPATIONAL
payloads up to 2300 kg and maximum reaches up to 4683 mm.
DISEASES AS WELL AS IT ENSURES THE CONSTANT QUALITY OF
PRODUCTS MANUFACTURED ACCORDING TO A COMBINATION OF
SPECIFIC PARAMETERS AND STANDARD PROCEDURES.”
Energy-saving The perfect CNC Starmatik Italy’s Flexible Bending System (FBS) is a system consisting of fully integrated components: robot,
cutting technology for press machines press brake, peripherals, hardware and software control. The advantage of having the robot, press brake and/or other
machinery and peripherals all integrated and communicating with each other reduces robot cell setup time, allowing
The FANUC CO2 Laser with 2D and 3D cutting techno­l­ogy FANUC’s unique CNC Power Motion i-A makes an ideal for a cost-effective production, no matter how large or small the batch size. Starmatik’s offline programming software
offers a reliable, precise and cost-effective way to cut alternative control for large servo applications such as “SimulEasy” permits to create and simulate programs for new parts while the robot cell is in operation.
sheet metal. Delivering superior parts fitting regardless of press machines. In practice, Power Motion i-A translates
material thickness, it also lowers your energy costs. That’s to less power consumption and more control and precision
because it contains smart features that reduce electricity than is possible using hydraulic technology. Thanks to
consumption by as much as 25% and gas consumption high-speed response features for quick axis start/stop and
by as much as 30%. To provide you with a full range of high-speed execution cycles, it also reduces cycle times
options, FANUC has also released a fiber laser. and keeps material stress to a minimum. Smoothing precision running for press machines: With torque
outputs up to 3000 Nm, FANUC Alpha iS servomotors are ideally
suited to large high-precision press machines.
 AUTOMOTIVE INDUSTRY 16 | 17

PSA Peugeot Citroën

Paris, France

Partnering
globally for more
productivity
Europe’s second largest car manufacturer, the PSA Group, has
improved efficiency at its plants around the world by installing
some 7000 FANUC robots on a range of automotive applications.

A pioneer in advanced body shop engineering, PSA was one of the first in the
automotive sector to adopt widespread use of electrically driven spot welding
guns, replacing air actuators with servo versions. Their enhanced reliability,
quality and cost-effectiveness have been recognised by most automotive
companies, who have since installed third-generation FANUC drive servo guns
with advanced features such as auto-tuning and battery-free gun change as
standard right across their operations.

ROBOTS EMPLOYED Recognition for its

PER SECTOR AT PSA: services to the PSA Group
“Working closely with FANUC to improve efficiency at its
BODY SHOP 6200 ROBOTS plants, the PSA Group recognised FANUC in 2009 and 2012
PAINT SHOP 240 ROBOTS for its outstanding performance in the areas of services,
industrial equipment and automotive parts. FANUC has been
SEALING 230 ROBOTS a PSA Core Supplier since 2012.”
ASSEMBLY 26 ROBOTS
POWERTRAIN 320 ROBOTS
Praise for a powerful partnership.
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Better body shop

The quality of a car body, including flawless panel fit and precision
welded seams, speaks directly to customers. Getting that right, 
Faster welding times
given the hundreds of panels and thousands of spot, stud and
seam welds that go into modern vehicles, demands a lot from
On spot welding applications that
suppliers and OEMs alike. That’s why FANUC body shop and panel demand the highest possible
welding solutions have been designed to deliver consistent welding number of parts per hour, FANUC
parameters, better weld quality and faster cycle times – something Learning Vibration Control (LVC)
software enables robots to learn
that is backed by an extensive package of welding solutions
the characteristics of a spot
and intelligent features designed to save you time and increase welding path in order to improve
productivity. These include functionality to ensure accurate parts cycle times.
The world’s fastest spot welding cell uses a FANUC CNC and robots.
fit up, weld logging capabilities as well as a range of synchronised
peripheral solutions to optimise external factors that impact cycle
times, such as handling, positioning or assembling.

Andreas Volprecht
Innovation: Flow Drill Screwing General Manager at LEWA Attendorn GmbH

Flow Drill Screwing (FDS) is a novel spot welding impossible, where the part designed for this kind of automotive
production process developed for the might need disassembling or where application. More rigid than other robots “IN THE BEGINNING, WE HAD OUR ENGINEERING IDEA. IN THE END,
automotive industry. Special fasteners metals are used that can’t be welded in this payload/reach range, it’s the
are inserted by a drilling and inserting together. It offers a flexible choice of perfect choice for processes that exert a THE FASTEST SPOT WELDING UNIT AVAILABLE – 40% FASTER THAN
process, providing a strong and rigid sheet metal type (steel, aluminium lot of pressure CONVENTIONAL SPOT WELDING SOLUTIONS.”
car body without the need for welding. and magnesium are supported) and is on the tool
easily combined with other assembly and require By combining the dedicated FANUC R-1000iA welding robot with a lightweight servo gun, leading German systems
FDS results in strong, high-quality car processes. Resistance to sideways heightened integrator LEWA Attendorn teamed up with FANUC to create the world’s fastest spot welding cell. In this cell the
bodies and components. It uses a self- and tilting forces is key to preventing precision. robot and LEWA’s SpeedGun can be operated using just one control. With additional software such as the Learning
piercing screw (i.e. it drills its own hole) the screw from slipping out and Vibration Control or the Dual Check Safety collision control, the SpeedGun is the ultimate high-speed solution when
and is ideal in situations where poor causing the process to fail. FANUC’s it comes to spot welding in confined spaces.
access to both sides of the part make new M-900iB/280 robot was specially

Unmanned operation
Robots versus traditional hem flange presses with laser

The process of roller hemming using robots was introduced as a cost-cutting measure. Although slower than Replacing spot welding on a
traditional flange presses, robots are considerably less expensive. They produce excellent results and can be used range of body shop applications, FANUC R-1000iA
on a wide range of materials, including steel and aluminium. Coordinating them with other assembly processes laser welding technology offers equipped with a LEWA SpeedGun
such as spot welding, gluing, riveting is also very straightforward. suppliers and OEMs alike high
stability, no deformation, high
In a typical roller hemming cell the workpiece is mounted in the fixture that presents the panels and their edges to one or welding speeds and lower
several robots. Bending is done gradually and the roller hemming may require 3 bending cycles to seal the hem completely. costs. Unlike older spot welding
Two additional robots can be installed in a single cell to achieve faster cycle times. In many instances, inserting and extracting solutions, laser also offers the
the workpiece into/from the fixture is also performed by robots. The new FANUC M-900iB robot offers just the right rigidity additional benefit of complete
for this process. unmanned operation.
FANUC M-900iB/280
www.fanuc.eu/M-900series
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Speed and flexibility

for your powertrain
production processes
The manufacture of automotive powertrains comprises a variety of machining processes that
demand maximum flexibility from CNC systems. The large variety of vehicle models, short product
life cycles and high volumes compound this further, meaning it is imperative for manufacturers to
simplify processes as much as possible. This involves reducing complexity, increasing efficiency and
focussing on seamless CNC systems that enable fast turnaround times between production runs as
well as high levels of throughput.

Maximum control,
maximum precision
FANUC’s 30i-B series CNC was purpose-built for fast, precise 5-axis machining
processes used in the automotive industry. Easy to use and featuring dedicated
automotive software, it provides the exacting levels of control required for
machining an infinite number of complex and sophisticated parts including
from camshafts, crankshafts and gears.
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EMAG Holding GmbH Matsuura Machinery GmbH Erwin Junker Maschinenfabrik GmbH Hembrug Machine Tools
Salach, Germany Wiesbaden-Delkenheim, Germany Nordrach, Germany Haarlem, Netherlands

“USED FOR THE PRODUCTION Matsuura is a leading machine tool manufacturer “FANUC ADVANCED CNC “CONTROL-RELATED FAILURES
whose CNC machining centres are used by BBS
OF POWERTRAIN COMPONENTS, Motorsport to produce high-specification wheels for
TECHNOLOGY GIVES JUNKER ARE VIRTUALLY NON-EXISTENT –
EMAG’S REVOLUTIONARY Formula 1 racing cars and other high-performance GRINDING MACHINES AN EDGE.” EVEN OVER THE LONGER TERM.”
vehicles.
VERTICAL TURNING MACHINE
Hard turning provides a fully-fledged alternative to
COMBINES DIFFERENT Fitted to high-speed 5-axis BBS’ Matsuura MAM72-63V Helping to put the high-speed in Junker’s high-speed
circular grinding on many automotive applications.
machining centres, FANUC 30i-A series CNCs provide grinding machines, FANUC Advanced CNC Technology
PROCESSES, INCLUDING the sophisticated level of control required by BBS comes with a wide range of features to reduce cycle
Hembrug, a pioneer of this technology, specialises
almost exclusively in fast ultra-precision hard turning
WORKPIECE PICKUP, HOLDING Motorsport. Matsuura equips its machines with FANUC times and increase the efficiency of oscillating
solutions.
CNCs given their incredible reliability and user-friendly crankshaft grinding processes. Leading to more speed
AND REMOVAL, IN ONE menu structures. Machining is not only very fast, but and accuracy, this includes Learning Control, minimal
Depending on the specifications, its Mikroturn range
CONTINUOUS COMPACT CYCLE.” the FANUC CNC also contains a number of software synchronous error between the spindle and feed axis,
of CNC lathes achieves incredible degrees of accuracy
features specifically designed to get the most from 5-axis faster execution of part program results and simplified
using either FANUC 0i-D or 32i CNCs. But accuracy
machining and fully utilise the machine’s potential. BBS programming.
For automotive suppliers this translates into incredibly was just one reason for choosing FANUC. Peter van
high process stability and huge time savings, no Production Manager Francisco Serrano provides a case Ommeren, Head of Electrical Design at Hembrug, says,
matter whether they are machining gearwheels, in point: “Recently we had to follow the path of bore “The combination of FANUC controls and drives in our
sprockets, sliding sleeves, components for CVTs, link holes, the diameter of which started at 0.4 mm and grew machines works wonderfully. That’s something we hear
pins, con rods, rockers, bearing rings or piston rings. increasingly larger. Even for the very small radii, the edges again and again from our customers. FANUC electrical
To coordinate these processes within their innovative had to be razor-sharp, which in turn required intricate components, motors and controls are built to the highest
machine, EMAG chose FANUC’s advanced 30i-B CNC. machining during milling. We were able to achieve perfect standards of quality and are extremely robust, even when
results with the FANUC-controlled Matsuura.” constantly exposed to electromagnetic forces.”
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Sophisticated machining Seamless CNC concept: The compact

is all about CNC FANUC 0i-F series CNC has been
specifically designed to provide a
straightforward solution for multiple
Demanding automotive machining operations often involve the use of multiple axes and tool paths.
To make these processes efficient, machining centres need to guarantee utmost precision and

control applications. Offering an

flawless surfaces within the shortest possible cycle times. They are, however, only ever as good as the
CNC that controls them. Fast, precise 5-axis milling, turning, grinding or cutting operations require a
CNC that delivers the exacting levels of control required for machining an infinite number of complex
and sophisticated automated parts – from camshafts, crankshafts and gears through to impellers. incredible degree of compatibility, the
0i-F series integrates seamlessly into
The world’s most reliable CNC  ANUC smart tip: Managed
F
FANUC’s 30i-B series CNC to provide users
is also the most flexible energy efficiency
with perfectly matched machine control
All FANUC CNCs, motors and
FANUC manufactures CNCs and machines dedicated to the production of automotive
components. Whether it’s milling, drilling, tapping, boring, complex machining or
amplifiers employ intelligent
energy management to ensure
regardless of the application. Since all
EDM wire cutting, FANUC has a solution to improve your cycle times and increase
throughput. Extremely reliable and designed for ultimate accuracy, FANUC products
can also be customised easily to handle a vast range of automotive applications.
they provide the best performance
for the lowest possible energy
consumption.
the hardware design and programming
is shared – something that completely
precludes the need for redundancies –, the
benefits of this ground-breaking approach
are significantly lower development and
setup costs.

FANUC CNC series + 0i-F & 31i-B

www.fanuc.eu/CNCseries

Every component in FANUC CNC systems – laser sources,

controls, motors and amplifiers – is exclusively developed,
manufactured and tested to perfection in-house.
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Versatile CNC
for efficient machining
Mark McFall
Rapidly changing production runs coupled with the need for complex parts – such Manufacturing Engineering Manager, Concentric AB
as camshafts, crankshafts or gears – to be machined to incredibly fine tolerances
require versatile CNC ­machines and machining centres that maximise efficiency
and drive increased productivity. As well as being extremely robust and reliable, they ”FOR OUR NEW OIL PUMP CELL WE WERE LOOKING FOR A SMALLER TAPER
need to offer huge versatility across a wide range of ­applications – from prototypes MACHINE WITH A FIXED TABLE AND A FOURTH AXIS IN THE FORM OF A
to entire production runs – while still delivering short cycle times. ROTARY INDEXER.”
In a dedicated cell, leading UK automotive supplier Concentric machines oil pump covers, pump bodies and transmission
pumps from pressure aluminium die-castings using FANUC’s versatile Vertical Machining Centre.

Competitively priced and extremely well suited to machining of this kind, the 30-taper, high-speed, vertical spindle machine
has significantly increased output for the automotive supplier. Explaining the reasoning behind the investment, Concentric
Manufacturing Engineering Manager Mark McFall says, “for our new oil pump cell we were looking for a smaller taper machine
with a fixed table and a fourth axis in the form of a rotary indexer. We opted for ROBODRILL due to FANUC‘s good reputation
in the market, especially for the reliability of their equipment. We went to see a similar machining centre that was robotically
loaded at a manufacturer locally and the feedback was all positive. The ROBODRILL was also ideally sized in terms of its tool
capacity as our applications require 20 tools and the machine’s turret-type magazine houses 21 cutters.“

ROBOCUT for superb surfaces even in poorly Top results thanks to precise interaction between highly
conducting materials and contact-free polishing. functional hardware and dedicated software features.

Reduce to the Speed and precision

max with Wire EDM beat raw power ROBODRILL has reduced machining times on aluminium pump bodies.

Replacing up to 8 conventional machining steps, including Instead of emphasising power, FANUC machining
pre-machining, hardening, finishing and fixturing, wire-cut solutions use intelligent cutting strategies to get better
EDM enables you to create extremely sophisticated forms results. The FANUC ROBODRILL, for instance, achieves
with incredible levels of accuracy. Since only one tool is the same results as bigger machines in less time. On
required, it is also your low-cost alternative to milling, high-speed machining, mould making or 5-axis machining
turning, grinding, lathing or broaching. operations it also looks up to 1000 blocks ahead.

FANUC ROBODRILL
High-Speed Vertical Machining Centre
www.fanuc.eu/robodrill
 AUTOMOTIVE INDUSTRY 28 | 29

Collaborative robots are currently a have to turn our minds to. In short the What kind of tasks can providers of

If it can’t do everything, does major talking point. How do you think this
technology will change the automobile
industry?
question remains: If it can’t do everything,
does employing a robot to do the job add up?
automation solutions to the automobile
industry expect to face over the next few
years?

having a robot add up? A well-known scientific belief is that 99% of

Where do you see collaborative robots
being used? And are today’s payloads
activities can be automated. But as far as and reaches sufficient?
“I’d say that
An interview with the automobile industry is concerned, I think
we need to be a little more differentiated.
Firstly, the term collaborative robot invites a
If we approach the question from
the perspective of ergonomics – i.e.,
automation
Markus Frischeisen, question – basically what do we understand
‘collaborative’ to mean? Today, it is generally
understood to mean passing a component to
collaborative robots doing the heavy lifting
for us humans – at 35 kg, the FANUC
CR-35iA is currently the only robot with
requires people
with the right
Head of Automation a human. But to me personally, collaboration
means humans and robots working together
on a vehicle. We use collaborative robots
a sufficient payload. None of the others
come close. The technology needs to
incorporate larger payloads and envelopes
skills.”
Development at AUDI AG in our production plant. They enable you
to remove traditional safety fences and let
humans and robots work together in the same
at an acceptable price. How does it help
me to have an extremely expensive robot
that won’t ever pay for itself?
Off the top of my head, I’d say that
automation requires people with the
right skills. Here we’re talking about
Mr Frischeisen, as far as the car industry intuitive if humans are going to understand components that offer energy-saving Intelligent, learning robots are also very different areas of specialisation –
is concerned, where do you see the
current challenges facing automation
and operate them quickly. It’s a bit like
the swipe technology on smartphones.
functions such as standby operation during
breaks in production.
“Big data mustn’t being discussed a lot. What role can
they play in improving processes?
especially IT for big data, robot technology
and artificial intelligence. Individual
technology? Ultimately though, big data mustn’t
be allowed to become an end in itself. What kind of progress do you expect to
be allowed to A big one. Right now collaborative and
providers won’t be able to provide this
kind of interdisciplinary approach. For
Well, one of the main challenges lies
in the fact that structures are currently
Predictive maintenance represents a good
case in point – logging huge amounts of
see in terms of alternative processing
and joining techniques, for aluminium
become an end in learning robots are hot topics within the
world of traditional industrial robots and have
that reason, partnerships will become
increasingly important – with other
undergoing some radical changes. Up data alone isn’t sufficient; the benefit for and composites for instance? itself.” a lot to offer. Nevertheless, we want them manufacturers as well as with universities.
to now, manufacturing a car body has users needs to be the ability to look into the to do more. For example, I can show a robot
involved around 10,000 to 12,000 network future. We want to know when the machine The automobile industry already uses most how to do something and have it incorporate
connections. That’s standard. But recently is going to fail if we’re going to be able joining techniques as standard. Bonding space. But that’s only the first step. Right what is has learned into its modular system.
the emphasis has switched to data. The to plan maintenance with any precision. and riveting, for instance, are widely-used now I’m not aware of a standard solution for Perhaps, for instance, there’s an item in a
buzzword is big data. We are adapting To do this, FANUC has just introduced its solutions. These are easily achieved; achieving the second step – having humans box that the robot has problems picking. I
to it progressively. Basically, automated Zero Downtime concept. We are really especially with the robots and dedicated and robots work together on the same want to be able to show it how to pick the
processes are becoming more data centric. looking forward to implementing this and tooling that support this type of joining component. Plus, there is also the question part by guiding it with my hand and, when the
These demand high-speed interfaces and, seeing how it moves us forward in terms of technology. The challenge is mostly posed of whether extensively automating processes next box arrives, have it pick it independently.
where devices are concerned, the ability predictive maintenance. Another issue is by composites. Where these are concerned, with collaborative robots makes financial What’s more, I want other robots doing the
to process larger volumes of data. This is the challenge posed by the persistent need the future demands faster, more precise sense? Perhaps a human can do it better? same job to access this information and to
closely related to the issue of operability. to save energy. Where this is concerned, joining processes in order to meet increasing Not forgetting the key issue of safety and create a kind of swarm intelligence without
Automation solutions need to be more we are always mindful to implement quality standards. workspace – it’s something we will always me having to invest heavily.
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Smarter painting
and dispensing
Paint application represents perhaps the most challenging process in vehicle manufacturing today.
Paint shop environments are hard on equipment, involve sophisticated processes and setups, non-
stop production and a high demand for energy. Today’s flawless paint surfaces and array of paint
options also demand zero fault tolerance, repeatability and unrelenting reliability from automated
systems. Given today’s shorter production runs and frequent model changes, these systems also
need to be highly adaptable. To meet the challenges of these environments, FANUC has designed
a dedicated range of paint robots that deliver incredible accuracy, maximised throughput and low
energy consumption in harsh environments. Coordinated FANUC robots handling and welding car underbody panels.

Intelligent painting
and coating General Motors Company
Detroit, Michigan, USA
FANUC's intelligent paint robots provide OEMs and automotive
suppliers with a competitive edge when it comes to painting
and coating applications, including painting in a chain-on-
edge conveyor. FANUC’s P-250iB robots series is designed to “COMPARED WITH CONVENTIONAL OVERHEAD CONVEYORS, M-2000iA
completely paint and coat a variety of products – all FANUC ROBOTS MAKE FOR GREATER SYSTEM RELIABILITY, INCREASED
paint robots are explosion-proof and fully ATEX compliant for
Category 2 and Group IIG. PRODUCTION AND LOWER MAINTENANCE COSTS. THEY ALMOST HALVE
THE SYSTEM FOOTPRINT AND ELIMINATE THE NEED FOR STRUCTURAL
REINFORCEMENT DURING INSTALLATION.”
Smart setup
Flexible low-cost lifting on a small footprint: At GM three FANUC M-2000iA/900L robots lift and transfer full vehicle bodies
through the underbody sealing and quality inspection process. Four FANUC M-20iA/10L robots use iRVision to locate seams
To reduce turnaround times on model changeovers, in the underbody area and then apply sealer using FANUC’s patented servo dispensing technology for maximum quality control.
FANUC has developed PaintTool™. Requiring very little or This is one example of the unique capability of the M-2000iA to lift an entire automotive body with its best-in-class payload and
no previous programming experience, this software tool working envelope. The M-2000iA robots eliminated the need for two custom engineered vertical lifts and a custom overhead
makes configuring and operating FANUC paint robots conveyor system.
easy. With a range of standard configurations on board, it
also saves time and provides adaptability across a host of
process parameter settings including colour change, line
tracking, path teaching and much more.

Find the complete FANUC paint robots range

www.fanuc.eu/painting
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Defying gravity Team up with a robot

and do more than ever before
The world’s strongest collaborative robot, the FANUC CR-35iA, lifts up to 35 kg and
operates completely without the need for fences. Designed to keep humans safe at all
times, it is ideally suited to a whole range of automotive processes that humans have
traditionally had to do alone, such as those involving heavy tools and powertrain
components. Depending on what you want it to do, it comes with either a FANUC
Vision Sensor or FANUC 3D Area Sensor.

The power and flexibility to lift entire cars through a range of processes.

With its huge 2.3 t payload, the new Capable of effortlessly lifting

FANUC M-2000iA opens up new and positioning an entire

car within its generous work

options for efficient assembly envelope, this robot has been

designed to improve workflow,
increase efficiency and reduce
Using large industrial robots like the FANUC M-2000iA/2300 on assembly operations to costs.
lift and position entire car bodies provides a flexible alternative to traditional hoists and
gantries. Not only do their smaller operating footprints save valuable floor space but they
also provide manufacturers with additional versatility thanks to a wide range of options.
Incredibly reliable and easy to maintain, they come with ISD energy-saving features.

CR-35iA Video
www.fanuc.eu/CR35iA
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”FANUC provides us with all the

Andrzej Marcinek
Managing Director of GEDIA Poland technical support and training
we need. Additionally, the robots
“FANUC ROBOTS HAVE HELPED our manufacturing processes. In terms of quality we have themselves are reliable and easy to
been able to achieve 100% repeatability. The robots have also
US FULLY AUTOMATE OUR
MANUFACTURING PROCESSES.”
given us the flexibility to implement the changes required by
our clients very quickly. They also allow us to manufacture
use, and are built with a minimum
German automotive supplier GEDIA relies on FANUC
several different components using one machine. Today, in
tough market conditions, they give us a significant advantage of moving parts using proven
robots to cut costs and meet growing demand at its by allowing us to react quickly to changing market trends.”
newly revamped plant in Poland. A supplier of pressed
metal components for cars and trucks, GEDIA has almost Automating GEDIA’s line has also helped to drastically reduce
solutions. FANUC also offers a wide
completely automated its manufacturing processes using
FANUC robots. Starting in 1994, automation at the plant
costs caused by human errors and mishandling, not to
mention workplace accidents. Installing the robots has also assortment of software tools to
stems mostly from the need to meet constantly increasing enabled GEDIA to take on additional staff to cope with the
quality and quantity requirements and carry out technically
advanced processes that would be extremely dangerous or
increased productivity at the plant. Since the dirty, heavy and
manually demanding work is now all completed automatically,
improve productivity and ensure
even impossible for manual operators. new employment opportunities have been created for persons
who, due to their age, gender or disability status, would have maximum precision.”
Currently the plant operates 57 FANUC robots, mostly on previously found it difficult to get work at the plant.
welding and spot welding applications but also on material Andrzej Marcinek, Managing Director of GEDIA Poland
handling operations. Welding and material handling Buoyed by this success, GEDIA is now in the process of
processes take place continuously at the plant and demand creating two additional production lines consisting of five
a very high level of precision and repeatability from the robots as well as a smaller one comprising three robots for
robots. Andrzej Marcinek, Managing Director of GEDIA riveting, bonding and laser welding. The decision has been
Poland, says, “FANUC robots have helped us fully automate reinforced by the company’s satisfaction with FANUC robots.

Dedicated spot welding robots ensure maximum

FANUC is at the heart of GEDIA’s spot welding cells. precision and improved cycle times.

FANUC robots give GEDIA the flexibility to react quickly to changing market conditions.
 AUTOMOTIVE INDUSTRY 36 | 37

Mr Höllen, for clients in the automotive Is this why you’re expanding your facility? but the benefits of centralising repairs are
sector recently there have been some that we can offer a complete service, get
positive changes to the way FANUC deals Yes, we need more space. We are about to direct support from Japan and have all
with repairs. How is this impacting the extend the Repair Center to include a further
European Repair Center in Echternach? 550 m2 of repair benches and warehousing.
And, for the first time in our history, we will
Well, for a start it has enabled us to carry be training apprentices – something that
out some exciting new developments. Since represents a major milestone for us. The
our founding in 1987, we’ve been providing expansion also enabled us to hire four new

Fast OEM repair support to Machine Tool Builders (MTBs)

across all our 16 European affiliates.
Currently we repair and overhaul about
repair technicians earlier this year.

Have things changed in other ways?

at the drop of a hat 1300 units a month. But due to intellectual

property rights restrictions, we have only
been able to do 70 percent of the repairs
The nature of our work is also changing
slightly. Originally our entire focus was

An interview with in-house, with the rest being sent back to

Japan. Until recently we simply didn’t have
test benches for more modern machines.
on CNC repair, but since 2010 we’ve been
repairing robot components too, mostly
motors. Business is growing and output is

Frank Höllen, starting to increase. Last year, for example,

we only had one technician doing motor
repairs but since then this figure has risen
the latest test equipment at our disposal.
Our increased output is evidence that our

Head of the FANUC to six. Instead of repairing 30 motors a

month, as was the case until recently, we’re
now doing 160. Plus services that were once
customers see it that way too.

Repair Center only available in Japan are now available in

Europe. Our technicians are also receiving
training in Japan, something that only
became possible recently. In fact we’ve got
Despite an industry-leading mean time between failures, now two there right now.

and again FANUC products do need to be repaired. Nevertheless,

Are there any other new angles to your
faced with contractual deadlines and enormous costs, automotive business?
suppliers and OEMs alike cannot afford to let this impact The newest product we were repairing was
production. To keep your downtime to an absolute minimum 15 years old. But that’s all changed now – Well, aside from our established exchange
and with the arrival of new tooling from and repair services that we’ve been growing,
and ensure you meet production schedules, FANUC has recently
Japan, we will soon be able to do 90 percent in January we started a teach pendant repair
expanded its dedicated European Repair Center to provide the of repairs here in Luxembourg, providing business from scratch. And we’ve gone from
spare parts and expertise you need whenever you need them. a faster response time to our European 0 to 50 units a month since the beginning
customers. of the year. Previously our affiliates did this,
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► AUTOMOTIVE INDUSTRY

Service first
With a global network covering every continent and more than 245 local offices in 46 countries,

Maximising
we are always there to meet your needs quickly and effectively, whenever you need us. In Europe,
a comprehensive FANUC network with 28 locations provides sales, technical, logistic and service
support throughout the continent. That way you can be sure to have a local contact that always speaks your uptime
your language.
Regardless of where you are in the
automotive supply chain, ensuring your
machines exhibit maximum reliability
is essential to your bottom line. That is
why having a maintenance strategy that
is ideally suited to you and your own

RE P
EN V

ES
TIVE
Lifetime FANUC Academy

VE SERVIC
MAINTENA
maintenance – training where

A CT I
you want it, when

RE
NC
E
As long as your machine is in service,
PR
ED
I CT I V
E MAINTE
NA
N CE
we will endeavour to provide you with
original spare parts for it – and that you want it
for a minimum of 25 years. If, for any
reason, we cannot do that we will In addition to an unrivalled range
individual needs is essential. At FANUC repair your components at the FANUC of courses in multiple languages at
we offer a whole range of individualised Repair Center to meet original quality locations across Europe, the FANUC
solutions – including preventative and specifications. Academy offers courses specifically
predictive maintenance packages – to tailored to the needs of the automotive
give you this flexibility and maximise industry. These can be taught in our
productivity. Everything is based on our real-life production environment
development guidelines to make products using the latest machines and control
as reliable, predictable and easy to repair technology, technology cell replicas
as possible. Backed by our enormous of your production facilities or at your
European stock of new and refurbished premises using our mobile training
OEM parts and ultra-fast delivery, our cells. Whatever option you choose, you
local OEM-trained service engineers will can be sure of the payoffs.
also repair, refurbish and retrofit your
machines to extend their lifespans and
save you money.

For FANUC’s full range of service and support offerings visit:

www.fanuc.eu/service
 AUTOMOTIVE INDUSTRY 40 | 41

ONE FANUC –
infinite opportunities

 ANUC – your one-stop solution

F
for robots, CNC, machining
centres and global services for
the automotive industry.
 MANUFACTURED EFFICIENCY: 5 PRODUCT GROUPS – ONE COMMON SERVO AND CONTROL PLATFORM
MBR-02401-EN-07/2017

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