PROJECTS
Project: Automated Seat Screw Fastening
Location: Slovakia and Czech Republic
Customer: Faurecia
Integrator: SIMERIS s.r.o.
Description: This project involved using a KUKA LBR IIWA R820_14 collaborative robot to fasten screws in seats on a production line
Key components:
Robot: 7-axis KUKA LBR IIWA R820_14 collaborative robot
Control System: Siemens S7-300/400 PLC
Human-Machine Interface (HMI): Proface
Vision System: Keyence CV-X100
Project: Automated Part Demolding for Injection Molding
Locations: Slovakia, Germany, France, Morocco, England, Poland
Customer: Plastic Omnium
Integrator: SIMERIS s.r.o.
Description: This project automated the removal of parts from injection molding machines from various manufacturers (Krauss Ma{ei, ENGEL, and YIZUMI). Six-axis robots from different brands were used depending on the specific cell.
Key components:
Robots: 6-axis robots (KUKA KR120 R3900, FANUC M-900iA/150P, ABB IRB 6650S- 90/3.9)
Control System: Siemens S7-1500 or Schneider PLC
Human-Machine Interface (HMI): WinCC
Project: Automated Insert Feeding for Injection Molding
Locations: Slovakia, Germany, France, Morocco, Poland
Customer: Plastic Omnium
Integrator: SIMERIS s.r.o.
Description: This project automated the process of feeding inserts into injection molding machines. A six-axis Fanuc LR Mate 200iD robot was used to pick and place inserts with precision and speed. Key components:
Robot: 6-axis FANUC LR Mate 200iD robot
Control System: Siemens S7-1500 PLC
Project: Automated Car Mirror Unloading
Location: Portugal
Customer: MORA
Integrator: SIMERIS s.r.o.
Description: This project automated the unloading of car mirrors from a production line and sorting them onto three separate conveyors. A six-axis KUKA KR10 R1100 robot provided the exibility and precision needed for this task.
Key components:
Robot: 6-axis KUKA KR10 R1100 robot
Control System: Siemens S7-300/400 PLC
Conveyors: Three separate conveyor systems for sorted mirrors
Project: Automated Car Bumper Labeling
Location: Poland
Customer: Plastic Omnium
Integrator: SIMERIS s.r.o
Description: This project automated the labeling of car bumpers using a combination of robots and a clever communication setup. An EVA robot specialized in label application was used, while KUKA, ABB, or FANUC robots (depending on the specific cell) handled the precise positioning of the bumpers. A Raspberry Pi 3 B+ with custom Python programming acted as a communication bridge between the di{erent components.
Key components:
Labeling Robot: EVA robot
Part Positioning Robots: KUKA, ABB, or FANUC robots
Control System: Siemens S7-1500 PLC
Communication Interface: Raspberry Pi 3 B+ (with Python programming)
Project: Automated Car Carriage Welding and Handling
Location: France
Customer: Renault
Integrator: SIMERIS s.r.o.
Description: This project involved automating the welding and handling of car carriages using powerful industrial robots. KUKA KR150 R3700 K ULTRA and FANUC R2000iB-210F robots were deployed to ensure precise and efficient welding trajectories and smooth handling of the car carriages within the production process.
Key components:
Robots: KUKA KR150 R3700 K ULTRA and FANUC R2000iB-210F robots
Project: Automated Parts Assembly and Welding for "ZB Konsole Gurtaufroller LI and RE"
Location: Czech Republic
Customer: SNOP
Integrator: SIMERIS s.r.o.
Description: This project automated the assembly and welding of parts, specifically for components related to seatbelt retractor mechanisms ("ZB Konsole Gurtaufroller LI and RE" translates to "ZB Console Seatbelt Retractor Left and Right"). A KUKA KR210 R2700 EXTRA C4 FLR robot was used for its reach, payload capacity, and welding capabilities.
Key components:
Robot: KUKA KR210 R2700 EXTRA C4 FLR robot Control System: Siemens S7-300/400 PLC
Project: Automated Part Assembly and Dual-Robot Welding System
Location: Slovakia
Customer: SNOP
Integrator: SIMERIS s.r.o.
Description: This project implemented a sophisticated automated system for assembling and welding parts, utilizing two KUKA robots with di{erent welding methods. A KUKA KR210 R2700 robot equipped with a welding gun performed welding operations on parts held in jigs. This setup provides exibility for welding complex geometries. A KUKA KR 150 R3100-2 robot worked in conjunction with a static welding gun. This dual-robot system increases efficiency and allows for simultaneous welding operations, optimizing the production workflow.
Key components:
Robots:
KUKA KR210 R2700 with a dynamic welding gun KUKA KR 150 R3100-2 with a static welding gun Control System: Siemens 1517F-3 PN PLC
Project: Automated Car Body Side Assembly
Location: Slovakia
Customer: Stellantis - PSA
Integrator: SIMERIS s.r.o.
Description: This project automated the assembly of car body sides using two FANUC R2000iB 175L robots. To ensure precise assembly, a Sick DT35-15551 sensor was used to accurately calculate the position of the car body parts. This sensor provides high-speed, non-contact measurement data to guide the robots in their assembly tasks.
Key components:
Robots: Two FANUC R2000iB 175L robots
Sensor: Sick DT35-15551 sensor for part positioning Motion Control:
Lenze drivers for conveyors SEW drivers for rotary tables
Project: Automated Car Hood Assembly
Location: Slovakia
Customer: Stellantis - PSA
Integrator: SIMERIS s.r.o.
Description: This project automated the assembly of car hoods using two FANUC R2000iB 175L robots. These robots handle and precisely position the hood and its various components (hinges, latches, etc.) for assembly and joining. A Sick DT35- 15551 sensor plays a critical role in accurately determining the position of the hood and its parts, ensuring proper alignment and fit during the assembly process
Key components:
Robots: 2 x FANUC R2000iB 175L robots
Sensor: Sick DT35-15551 sensor for part positioning Project: Automated Car Body Brushing
Project: Automated Car Body Brushing
Location: Slovakia
Customer: Stellantis - PSA
Integrator: SIMERIS s.r.o.
Description: This project automated the brushing process in the final assembly stage ("completion area") of car manufacturing. A FANUC R2000iC robot equipped with a Ferrobotics brushing tool was used to perform surface finishing operations on the car body. This involves tasks like removing dust, debris, or smoothing out imperfections before the ~nal paint application.
Key components:
Robot: FANUC R2000iC robot
Brushing Tool: Ferrobotics brushing tool
Project: Automated Car Body Brushing
Location: Slovakia
Customer: Stellantis - PSA
Integrator: SIMERIS s.r.o.
Description: This project automated the brushing process in the final assembly stage ("completion area") of car manufacturing. A FANUC R2000iC robot equipped with a Ferrobotics brushing tool was used to perform surface finishing operations on the car body. This involves tasks like removing dust, debris, or smoothing out imperfections before the final paint application.
Key components:
Robot: FANUC R2000iC robot
Brushing Tool: Ferrobotics brushing tool
Project: Automated Screw Fastening for Car Carriages
Location: France
Customer: Stellantis - PSA
Integrator: SIMERIS s.r.o.
Description: This project automated the process of fastening screws in car carriages using a Universal Robot UR10. This collaborative robot (cobot) is wellsuited for this task due to its exibility, safety features, and ease of programming. It works alongside human workers to improve efficiency and ergonomics in the car assembly process.
Key components:
Robot: Universal Robot UR10 (collaborative robot)
Project: Automated Injection Molding with Complex Insert Handling
Location: France
Customer: Saint Gobain
Integrator: SIMERIS s.r.o.
Description: This project involved a highly automated system for loading and unloading 48 inserts into the matrix of an injection molding machine. The complexity of handling so many inserts requires a sophisticated setup with multiple robots, cameras, and a well-coordinated material handling system.
Key components and processes:
Robots: 2 x KUKA SCARA robots for precise and fast insert handling. SCARA robots are ideal for this application due to their speed and accuracy in vertical movements.
Insert Feeding: A vibrating bowl and two conveyors supply the robots with inserts.
Vision Systems:
1 x CIRA camera for quality inspection of the inserts.
2 x Cognex cameras to verify the position of the inserts before placement by the robots.
Matrix Unloading: A 2-axis system unloads the ~nished parts from the matrix after the injection molding cycle is complete.
Finished Product Handling: Three conveyors transfer the finished products to an operator station for further processing or inspection.
Control System: Siemens PLC 1500 with Pro~safe for safety functionality.
Motion Control: 8 x Lenze inverters for precise control of motors and actuators in the system.
Project: Automated Production of Hydrogen Electrolyzers
Location: Italy
Customer: Mcphy Italia
Integrator: Snef Slovensko s. r. o.
Description: This project automated the production of hydrogen electrolyzers.
Key components:
Robots: FANUC robots for handling and assembly tasks within the electrolyzer production process.
Profilers: Keyence LJ-8400 profilers for precise measurement and inspection of electrolyzer components to ensure quality and accuracy.
Control System: Siemens S7-1515SP PC-based PLC for controlling the robots, profilers, and other automation equipment.
Human-Machine Interface (HMI): Siemens MTP1500 Unified Comfort panel for operator interaction and system monitoring.
Project: Automated Welding Cell for Car Carriages
Location: Germany
Customer: OPEL
Integrator: SIMERIS s. r. o.
Description: This project involved the design and implementation of a highly automated welding cell for the production of new car carriages. The cell utilizes a combination of FANUC robots specializing in different welding techniques,.
Key components and processes:
Spot Welding Robots: 3 x FANUC robots dedicated to spot welding, a process that joins metal sheets by applying pressure and electric current at specific points.
Projection Welding Robots: 2 x FANUC robots for projection welding, a technique where small projections on one of the workpieces are melted to create the weld. This is used for joining nuts, studs, or other components to larger parts.
Control System: Siemens S7-400/300 PLC programmed to OPEL's specific standards, ensuring seamless integration with existing production systems.
Project: Automated Bonding Cell for Audi Q9 Tailgates
Location: Slovakia
Customer: Plastic Omnium
Integrator: Snef Slovensko s.r.o.
Description: This project involved the creation of a sophisticated automated bonding cell speci~cally for the production of Audi Q9 tailgates. The cell utilizes multiple FANUC robots and specialized equipment to perform various bonding and surface treatment operations.
Key Processes and Equipment:
Robotic Handling: 5 x FANUC robots handle di{erent tasks within the cell, including: Applying adhesive (gluing)
Gluing and Priming: Two Delta machines are dedicated to automated gluing and priming applications.
Flaming: 2 x Ipros aming systems provide precise and controlled ame treatment of the tailgate surfaces.
Heating: Leister heating systems used to cure adhesives or prepare surfaces for bonding.
Traceability: Zenon software provides traceability and process monitoring, ensuring quality control and data logging.
Motion Control: 11 x SEW drivers control the movement of robots and other automated equipment within the cell.
Control System: 2 x Siemens PLCs (S7-1517F-3 and S7-1515) manage the complex automation sequences and integrate all cell components.