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FANUC robots at Opel in Hungary

Collaborative screwing in engine production


Cooperative screwing robots - application with a collaborative FANUC Cobot CR7-ia at Opel in the Hungary plant during engine assembly

With the FANUC CR-7ia HRK applications can be implemented using the sensitive sensors built into the base. To implement this cobot screw connection, the greatest challenge was to design the screwdriver securely so that the worker can work right next to the cobot.

FAUDE’s task in this project was to design the screwdriver protection, integrate, program and commission the robot on the system.

As one of the largest European car manufacturers, Opel sold around 1.13 million vehicles in 2017. The ultra-modern engine plant in Szentgotthárd produces the new, very economical 3- and 4-cylinder petrol and diesel engines.

The aim of the Opel plant in Hungary is to be able to react quickly to the changing market through a high degree of flexibility. Therefore, in recent years, several development projects have been carried out in Szentgotthárd in cooperation with FANUC. One of these projects was to install an innovative collaborative robot application from FAUDE in the production line.

Due to the large number of FANUC robots already installed in a factory, both in flexible production and on the assembly line, a FANUC cobot should also be used for collaborative robot applications. The aim was to install a collaborative robot on the production line that works side by side with humans. This should make the workers’ working life easier and the monotonously stressful task of screwing should be taken over by a robot. In addition, the focus was on increasing productivity while maintaining quality.

The biggest challenge of the project was to make the tool – in this case a screwdriver – secure so that no injuries could occur during operation. The most important thing here was the optimal design of the screwdriver housing. By using large radii on a 3-D printed part, the specified limit values of TS15066 could be adhered to. The integrated lighting shows the current working status of the cobot and thus improves the safety requirements of DIN ISO 10218. Thus, the cobot is a reliable and predictable colleague for the operators in the workplace next to it.

The built-in FANUC CR-7iA itself does not need a protective fence, as it has proven sensors in the base that automatically bring the cobot to a standstill if a collision with a solid object or a person occurs.

Of course, there were many questions from Opel employees in advance as they familiarized themselves with the technology. However, all doubts disappeared during operation in the test production phase. Today the operators treat the FANUC robot as their colleague, as a cobot!


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