Door Removal Manipulator

In the automobile assembly line, the weight of the workpiece to be transported (is it over 15kg?) is no longer a key indicator used to distinguish between manual handling and labor-saving equipment handling.

Here, reducing the labor load is no longer the only appeal, and the focus instead is:

  • quality! Products must have zero defects. It is necessary to make the weight of the workpiece no longer an influencing factor that lowers the product qualification rate. 
  • Beats! Faster than faster. What we are striving for is to continuously increase the output, and constantly beat the production beat of each station. We are no longer satisfied with 60JPH, and must march towards 70JPH and 85JPH! 
  • Process optimization! Reanalysis and optimization of all details.

Q: Why do the doors need to be removed?

A: Body-in-white, after passing through the painting workshop, all car parts are painted with brand new paint. After entering the final assembly workshop, the first thing to do is to disassemble the door, put the door into the door subassembly line, assemble the door trim, wiring harness, etc. to the door, and then assemble the door assembly to the car body.

About the Door

For passenger cars, the style, size and weight of the doors vary greatly among different brands and models, usually 1200~1500mm wide, 1400~1600mm high, 200~350mm thick, and 22~26kg in weight.

Figure 1: The Worker is Removing the Door

System Configuration

Track system: "low damping type" aluminum alloy track 7m*2 pieces 

  • Walking trolley: Hand-pulled mobile trolley 
  • Host model: PBF-SM100 
  • Host parameters: Rated load G=100Kg Service radius R=2500mm Working stroke H=1200mm 
  • Clamp style: dynamic clamp 
  • Host control mode: empty/load automatic switching 
  • System working pressure: above 0.6MPa 
  • System air consumption: 300L/min 
  • Quantity: 1 set of manipulators on each side, 2 sets in total

A:System Overview

 Figure 2: Door Removal Manipulator

This scheme is used for the power-assisted manipulator system for labor-saving operation of tire installation. The system adopts a special fixture for tire installation, and is equipped with an empty/load automatic switching balance control system. After the load is suspended, it is in a floating state at any position within the stroke, which is convenient for precise positioning.

B:Track System

Figure 3: Door Removal Manipulator

The power-assisted manipulator track system adopts modular installation components, which is convenient for on-site track adjustment and installation in different occasions. 

The track system of the power-assisted manipulator adopts low-damping aluminum alloy track, which has excellent wear resistance and strength, and ensures that the whole system can run smoothly, with low resistance and no noise, and is safe to use and neat in appearance.

About the Host

Figure 4: Door Removal Manipulator

  • The design of the PBF main engine cleverly applies the principle of force balance. After the load is suspended, it is in a gravity-free floating state at any position within the stroke, which is convenient for the operator to accurately position and labor-saving assembly.
  • The PBF host has the characteristics of smooth movement and rigid structure, which makes the transfer and assembly of materials easy and fast. 
  • The PBF main engine adopts the empty/load automatic switching balance control system to ensure that the manipulator is in a floating balance state when it is empty or loaded, which is convenient for operation and positioning. 
  • The main engine of PBF is equipped with an air cut-off protection device. When the main air supply source is accidentally cut off, the power-assisted mechanical arm will not suddenly fall. 
  • The PBF host is equipped with a misoperation protection function, and the workpiece can only be unloaded when it is effectively supported to ensure the safety of the working process.

About Claws

Figure 5: Door Removal Manipulator

  • The fixture of this scheme is a fixture scheme for labor-saving operation when installing the car door. 
  • The fixture of this scheme is a dynamic fixture, which realizes the grasping and other actions of the workpiece. 
  • The system is equipped with a load indicator, when the workpiece is lifted, the indicator is red. 
  • The system is equipped with a misoperation protection device, which can only be unloaded after the workpiece is effectively supported, so as to ensure the safety of the workpiece and the safety of the operator when unloading. 
  • The system is equipped with soft protective materials and protective covers at the corresponding parts to avoid scratching the workpiece. 
  • The control handle is integrated into the custom clamp, allowing the operator to control the positioning of the material with both hands simultaneously.

Figure 6: The Worker is Removing the Door

Of course, from the point of view of product selection, if the on-site workstations are spacious enough and the working rhythm allows, a soft cable manipulator can also be arranged, with low investment cost and simpler operation.

About Safety

Figure 7: The Worker is Removing the Door

Anti-fall safety protection wire rope 

Oil pressure buffer limit at the end of the track 

Early warning position and emergency stop position: This system and the main line system can build a safe interaction mechanism. There are two travel limit switches at the end of the track. When the moving trolley touches the first limit switch, the system will give a buzzer alarm; when the moving trolley touches the second limit switch, the system will send Line stop signal, the main line stops running. 

The system is equipped with 4 mechanical stops to ensure safety.

Small Workpiece Handling Solution