Automotive Parts Roll Forming & Deburring Automation with Kawasaki and ABB Robots

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Automotive Parts Roll Forming & Deburring Automation with Kawasaki and ABB Robots

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Application Field: Industry > Automotive, Application > Loading·Unloading, Application > Deburring·Post-processing, Sector > Manufacturing

Industry > AutomotiveApplication > Loading·UnloadingApplication > Deburring·Post-processingSector > Manufacturing

#RollFormingAutomation#RoboticDeburring#KawasakiRobot#ABBIRB2600#ABBIRB6700#InLineTransfer#CycleTimeReduction#ProductivityImprovement

Process Overview

This solution uses a total of four robots—one KAWASAKI ZX165U, two ABB IRB 2600 units, and one ABB IRB 6700—to transfer automotive parts after roll forming and perform deburring operations.

By transferring parts to the next process in sync with the continuous forming cycle time, it reduces operation time and maximizes productivity.

Components

Robot	KAWASAKI ZX165U 6-axis articulated robot Payload: 165 kg Working radius: 2,651 mm Weight: 1,350 kg Repeatability: ±0.3 mm ABB IRB 2600 (x2) 6-axis articulated robot Payload: 20 kg Working radius: 1,650 mm Weight: 272 kg Repeatability: ±0.04 mm IP67 ABB IRB 6700 6-axis articulated robot Payload: 235 kg Working radius: 2,650 mm Weight: 1,250 kg Repeatability: ±0.05 mm
Peripherals	Pneumatic gripper (x1) Deburring tool (x2) Vacuum gripper (x1) Robot mounting base (x4) Machined part transfer pallet Roll forming equipment (separate component)

Workflow

STEP 1.	Wait for roll forming completion
STEP 2.	Grip roll-formed part (ZX165U)
STEP 3.	Unload to transfer pallet (ZX165U)
STEP 4.	Deburr formed part ends (IRB 2600)
STEP 5.	Unload to stacking pallet (IRB 6700)

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Features

Improves both work environment and productivity
Secures high productivity through continuous operation with minimal downtime
Prevents safety accidents by removing operators from hazardous tasks
Automates the continuous process from roll forming to deburring
Improves quality by utilizing high-precision robots
Enables optimal design and pre-validation based on process conditions
Supports custom tool design and fabrication optimized for roll forming conditions and performance
Reduces operation time by synchronizing tasks with the production speed of upstream equipment

Results

Key Benefits	Improved work environment through unmanned hazardous operations Increased productivity through shorter cycle time and continuous production
Client Feedback	By automating continuous processes, production speed improved significantly and machining quality was enhanced.

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