Automotive Component Assembly Automation using Epson C4 + FT Sensor

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Automotive Component Assembly Automation using Epson C4 + FT Sensor

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Application Field: Industry > Automotive, Application > Assembly, Sector > Manufacturing

Industry > AutomotiveApplication > AssemblySector > Manufacturing

#PrecisionAssembly#PressFitInsertion#EpsonRobot#ForceTorqueSensor#AutomotiveAssembly#PinInsertion#TaktTimeReduction#DefectReduction

Process Overview

This assembly automation solution uses an Epson C4 robot and an FT (Force-Torque) sensor to automate the task of inserting and fastening automotive parts with a tight press-fit tolerance.

Even when the fit is extremely tight, the system can detect insertion force, locate the correct position, and perform smooth insertion without part damage or jamming.

This project was implemented to automate the insertion of fixing pins used in automotive components.

Components

Robot	Epson C4 6-axis articulated robot Payload: 4 kg (rated 1 kg) Max reach: 600 mm Weight: 27 kg Repeatability: ±0.02 mm
Peripherals	SMC 3-finger pneumatic gripper 6-axis FT (Force-Torque) sensor S250 (high rigidity, high sensitivity) Rated load: 250 N / 18 Nm Resolution: 0.1 N / 0.003 Nm Measured components: force (X, Y, Z) / moment (Fx, Fy, Fz) — 6 axes Work cell Robot base Part rack and fixing jig

Workflow

STEP 1.	Pick the lower part and place it at the assembly position
STEP 2.	Clamp and secure the workpiece
STEP 3.	Pick and insert the connecting pin
STEP 4.	Pick the upper part and align to the pin position while rotating for insertion

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Features

Enables high-precision insertion operations
Ensures precise insertion even with micro-level tolerances by applying an FT sensor capable of detecting 0.1 N / 0.003 Nm and high repeatability
Detects and compensates for pin position error and tilt direction through force-direction sensing
Prevents part damage during insertion/assembly through precise force sensing
Enables controlled insertion by adjusting force even with part shape variation
Enables compact installation
Minimizes installation and operation space through compact robot form factor
Minimizes takt time through high-speed operation
Enables high-speed operation with a maximum joint speed of 720 deg/s
Provides assurance through quality warranty coverage
Provides 1-year warranty service support

Results

Key Benefits	Reduced labor input for automotive pin insertion operations
Client Feedback	For pin insertion, the tolerance was extremely tight at a 10-micron level, making even manual assembly difficult. Automation had been delayed, but through Dream’s solution, automation became feasible.

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