Automated Adhesive Application Cell with ABB Robotics and Virtual Commissioning

<h2>Project Overview</h2>

<p>A global automotive OEM required the implementation of a new automated adhesive application cell within an existing paint shop production environment.</p>

<p>The process involved the application of structural adhesive material on vehicle body joints using ABB robotics while maintaining strict quality requirements and supporting multiple vehicle models. The solution required robotic automation, industrial vision systems, operator interfaces, process redundancy, and integration with existing plant control systems.</p>

<h2>Challenge</h2>

<p>The customer required a highly reliable automated process capable of applying adhesive material with repeatable quality while maintaining production flexibility and supporting multiple vehicle variants.</p>

<p>The project required the integration of robotics, process technology, industrial vision systems, safety systems, and Siemens PLC controls within an active automotive manufacturing environment.</p>

<p>Additionally, the system required automated quality verification through vision inspection while maintaining an existing manual rework process for units that did not meet quality requirements.</p>

<h2>Engineering Solution</h2>

<p>Tech Automation supported the development and implementation of a fully automated adhesive application cell utilizing ABB robots, Siemens controls, industrial vision systems, and virtual commissioning methodologies.</p>

<p>The system incorporated two ABB robots operating on 7th-axis motion systems, dual adhesive dosing pumps, six quality inspection cameras, operator interfaces, safety systems, and communication with plant automation infrastructure.</p>

<p>Following adhesive application, vision systems verified process quality. Units that failed inspection could be routed to an existing manual rework area, providing an additional layer of quality assurance while maintaining production continuity.</p>

<h2>Project Scope</h2>

<ul>
<li>ABB Robot Programming</li>
<li>Offline Programming (OLP)</li>
<li>Virtual Commissioning</li>
<li>Pre-Commissioning Activities</li>
<li>Paint Shop Commissioning</li>
<li>Operator Training</li>
<li>Production Support</li>
<li>Cybersecurity Integration</li>
<li>Safety Validation</li>
<li>Documentation Development</li>
<li>HMI Development</li>
<li>Industrial Networking</li>
</ul>

<h2>Technologies Used</h2>

<ul>
<li>ABB Robots with 7th Axis Motion</li>
<li>Siemens S7-1500F PLC</li>
<li>Industrial Vision Systems</li>
<li>Adhesive Dosing Systems</li>
<li>Profinet Communication</li>
<li>Industrial HMI Systems</li>
<li>Automotive Paint Shop Automation</li>
<li>Virtual Commissioning</li>
<li>Cybersecurity Integration</li>
</ul>

<h2>Production Features</h2>

<ul>
<li>Two ABB robots with 7th-axis travel units</li>
<li>Support for multiple vehicle models</li>
<li>Automated adhesive application</li>
<li>Dual dosing pump architecture</li>
<li>Vision-based quality verification</li>
<li>Manual rework process integration</li>
<li>Industrial HMI operation</li>
<li>Automotive manufacturing standards compliance</li>
</ul>

<h2>Results</h2>

<p>The project successfully implemented a fully automated adhesive application process capable of supporting multiple vehicle models while maintaining quality verification through industrial vision systems.</p>

<p>The solution improved process consistency, reduced quality variation, enhanced operator visibility, and increased production reliability through integrated automation and quality inspection technologies.</p>

<p>Through the use of virtual commissioning, offline programming, and structured startup activities, project risk was reduced and commissioning activities were streamlined.</p>

<h2>Key Benefits</h2>

<ul>
<li>Automated adhesive application process</li>
<li>Vision-based quality verification</li>
<li>Support for multiple vehicle models</li>
<li>Integrated manual rework strategy</li>
<li>Improved process consistency</li>
<li>Reduced quality variation</li>
<li>Virtual commissioning prior to startup</li>
<li>Enhanced production flexibility</li>
<li>Improved operational reliability</li>
<li>Automotive manufacturing compliance</li>
</ul>