Robots line-side at engine manufacturer

Parts at the FPT Industrial plant in France are large and heavy, and with the specific tools needed for their assembly, the pallets were taking up too much space in the assembly line. Parts flow management and operator movements were not optimised. 

FPT logistics product manager Ms. Faivre, explains: “We wanted to improve the logistics flow and the working conditions of our operators.”

To achieve its objectives, FPT called on Sherpa Mobile Robotics and its mobile and collaborative robots. Unlike AGVs, these AMRs do not rely on dedicated paths. They are programmable to be able to adapt to their environment. 

Sherpa Mobile Robotics (SMR) proposed a complete reorganisation of the assembly line with the support of a fleet of six robots managed by its Fleet Management System software.

How it works

The assembly was reorganised into two parallel lines separated by a central aisle. One line is dedicated to the preparation of the sub-assemblies and the other to the assembly of the 150 engines to be produced each day, working in two shifts. The six robots are deployed in twos, two each for the three assembly stations for motor supports, motor flywheels and basins. At the robot’s departure point, one person prepares the parts.

When the robot arrives at the assembly line, another person is there to receive the parts. The robots have three programmed missions for each of the assembly stations. Each robot brings a prepared and assembled sub-assembly from the preparation area to the assembly area and then returns.

Central to this organisation is line side management that is both automated and mobile. The operators stay in their work area. The Sherpa robots come to them, carrying the parts and specific tools. The parts are prepared elsewhere, in the preparation line, where they are unpacked and laid out ready for assembly, along with the necessary tools. Using this fleet makes assembly tasks less arduous and reduces the risks associated with transporting loads. 

The robots are used 20 hours a day. In total, 450 robot missions are carried out daily.

“By increasing our productivity and getting closer to one piece flow, these robots are fully in line with our 4.0 strategy,” says Faivre.

Safety

Sherpa robots can move about in the midst of operators, trucks and AGVs. Each robot is equipped with a Lidar (360° laser navigation sensor), a robust and reliable localisation system and safety sensors to detect obstacles on the ground. The sensitive edges stop the robot if it touches an obstacle. Their safety electronics provide the means of verifying that the various instructions given to the external elements (motors, sensors, etc.) are correct.

Management

Sherpa Mobile Robotics has developed its own Fleet Management System (FMS). The software offers a mapped view of the work area showing the robots' movements, with mission indicators (time, movement, charge, etc.) for each robot along with their battery status. A Shercom module indicates the traffic in the area of the robots.

For more information, visit www.sherpa-mr.com