Visvesvaraya Technological University Belgaum, Karnataka-590018 PROJECT REPORT [10AU85] ON “APPLICATION OF COBOTS IN AUTOMOTIVE ASSEMBLY LINE” Submitted In partial fulfillment of the requirement for the award of the Degree of BACHELOR OF ENGINEERING IN AUTOMOBILE ENGINEERING By PRAFULLA V (1NH13AU046) BALU KRISHNAKUMAR MENON (1NH14AU007) Under The Guidance of Mrs. SMITHA B. S. Assistant Professor Department of Automobile Engineering, NHCE 2017-2018 NEW HORIZON COLLEGE OF ENGINEERING (Autonomous college Permanently Affiliated to VTU Approved by AICTE) Accredited by NAAC with ‘A’ Grade DEPARTMENT OF AUTOMOBILE ENGINEERING CERTIFICATE This is to certify that the Project Report [10AU85] on APPLICATION OF COBOTS IN AUTOMOTIVE ASSEMBLY LINE is bonafide work carried out by PRAFULLA V (1NH13AU046) BALU KRISHNAKUMAR MENON (1NH14AU007) In partial fulfillment for the award of degree of Bachelor of Engineering in Automobile Engineering of the Visvesvaraya Technological University, Belgaum during the year 2017-2018. It is certified that all corrections/suggestions indicated for Internal assessment have been incorporated in the report deposited in the departmental Library. The project report has been as it is satisfying the academic requirements in respect of project report prescribed for the Bachelor of Engineering Degree. Signature of Internal Guide Signature of HOD Signature of Principal External Viva Name of the Examiners Signature with Date 1 2 ACKNOWLEDGEMENT The satisfaction that accompanies the successful completion of any work would be incomplete without the mention of people who made it possible and whose constant encouragement and guidance has been a source of inspiration through the course of completion of this project. We wish to thank the Almighty for all the blessings we have received. We express our heartfelt thanks to Dr. Mohan Manghnani, Chairman, New Horizon Educational Institutions for providing this endower. We would also like to express our heartfelt thanks to Dr. Manjunath, Principal, New Horizon College of Engineering for providing a friendly atmosphere to work in. Any amount of gratitude is incomplete without thanking Dr. Sridhar Kurse, Professor and HOD, Department of Automobile, New Horizon College of Engineering who has continuously supported and motivated us in completion of this project. We sincerely thank Prof. Karthik A.V, Assistant Professor, Department of Automobile, New Horizon College of Engineering who has guided us throughout the completion of this project. We thank the entire staff members of automobile Department, New Horizon College of Engineering and everyone who has directly or indirectly helped us in completion of the project. Declaration We, Akarsh, Aldwin Rajan, D Praveen, Ashwin Unnikrishnan students of 8th Semister, B.E Automobile Engineering, New Horizon College of Engineering declare that the project work titled “Influence Of Canola Oil On Performance And Emission Characteristics Of A Single Cylinder Diesel Engine” has been carried out by us and submitted in partial fulfilment of course requirement for the award of degree in Bachelor of Engineering in Automobile Engineering of Visvesvaraya Technological University, Belgaum, during academic year 2017-2018. Date: Place: PRAFULLA V. (1NH13AU046) BALU KRISHNAKUMAR MENON (1NH14AU007) Application of cobots in automotive assembly line Table of Contents Chapter 1 - Introduction 1.1 – Abstract 1.2 – Project objective Chapter 2 – Company Profile 2.1 About Continental AG 2.2 Key milestones 2.3 Company mission 2.4 Company values Chapter 3 – Cobots 3.1 Introduction to cobots 3.2 Types of cobot operation 3.3 Cobot lifespan 3.4 Cobot applications Chapter 4 – Selection 4.1 Of YSD line 4.1.1 Data 4.2 Of cobot Chapter 5 – Components 5.1 Gripper design and validation Department of Automobile Engineering, NHCE Page 1 Application of cobots in automotive assembly line 5.1.1 Repeatability 5.2 PCBs 5.2.1 PCB defects Chapter 6 – Change of Location 6.1 – Data 6.2 Gripper validation 6.3 Risk assessment 6.3.1 Risk analysis 6.3.2 Risk evaluation 6.3.3 Poka Yoke 6.4 Cobot operation Chapter 7 – Result Chapter 8 – References and literature review 8.1 – Technical papers 8.2 – Cobot safety and programming 8.3 – Case studies 8.4 – Related articles Department of Automobile Engineering, NHCE Page 2 Application of cobots in automotive assembly line Chapter 1 - INTRODUCTION 1.1 Abstract Founded in Hanover, Germany in 1871, Continental AG can look back at a history of success. As an automotive supplier and industry partner, the technologies, system and service solutions on offer make mobility and transport more sustainable, safer, more comfortable, more customised and affordable, that help protect the environment and that give individuals more opportunities to shape their own future. Collaborative robots, or cobots, are complex machines which are designed to work hand in hand with human beings. In a shared work environment, they support and relieve the human operator. This helps free up the human operator to be deployed elsewhere on different assignments as required. Consequently, this saves countless man- hours and increases production rates as well as production efficiency exponentially. 1.2 Project objective The project deals with the implementation of cobots on the shop floor of a production plant, namely Continental Automotive India, to free up manpower and increase production as required in response to demand. One area where installation of the cobot would benefit production is the installation of speedometer needles or pointers, on Printed Circuit Boards (PCBs). The application of the cobot is such that it could carry out jobs on multiple workstations within its operable workspace. A deeper look is carried out in the following chapters. Department of Automobile Engineering, NHCE Page 3 Application of cobots in automotive assembly line Chapter 2 – COMPANY PROFILE 2.1 About Continental AG Continental AG is a leading automotive manufacturing company specialising in tyres, brake systems, interior electronics, automotive safety, powertrain and chassis components, tachographs, and other parts for the automotive and transportation industries. They are the world’s fourth largest tyre manufacturer, after Bridgestone, Michelin and Goodyear. Starting as a rubber manufacturer in 1871, Continental was ranked third in global OEM automotive parts sales in 2012 according to a study sponsored by PricewaterhouseCoopers, sfter the acquisition of Siemens AG's VDO automotive unit in 2007. In 2008, Continental appeared overextended with its integration of VDO and had since lost almost half of its market capitalisation when it found itself to be the takeover target of the family-owned Schaeffler AG. By 2009, Schaeffler successfully installed the head of its motor division at the helm of Continental. Schaeffler AG is the controlling shareholder and currently owns 46% of Continental shares. Continental is structured in five divisions: Chassis and Safety Powertrain Interior Tyres ContiTech Department of Automobile Engineering, NHCE Page 4 Application of cobots in automotive assembly line One of Continental's main areas of expertise and technological leadership is fuel consumption reduction, achieved through more efficient fuel injection systems, reduced rolling-resistance tyres, and hybrid propulsion systems. Continental sells tyres for automobiles, motorcycles, and bicycles worldwide under the Continental brand. It also produces and commercialises other brands on a regional level, such as General (US/Canada), Gislaved (Canada, Spain, Nordic Markets), Semperit (industrial applications), Euzkadi (Mexico/Latin America) and Barum to serve EU & Russia. Continental's customers include all major automobile, truck and bus producers, such as Volkswagen, Daimler AG, Ford, Volvo, Iveco, Schmitz, Koegel, Freightliner Trucks, BMW, General Motors, Toyota, Honda, Renault, PSA and Porsche. Continental tyres on a Mercedes-Benz SLS AMG In 2001, Continental acquired a controlling interest in Temic, Daimler Chrysler's automotive-electronics business, which is now part of Continental Automotive Systems. The company also purchased German automotive rubber and plastics company Phoenix AG in 2004, and the automotive electronics unit of Motorola in 2006. Continental acquired Siemens VDO from Siemens AG in 2007. In Argentina, teamed up with FATE in 1999 for the production of tyres for cars, trucks, and buses and exports the production of the San Department of Automobile Engineering, NHCE Page 5 Application of cobots in automotive assembly line Fernando plant to the rest of South America. In 2007, the company began to construct a plant in Costa Rica to produce powertrain components for North America. Continental also produces wheels for (mountain) bikes and continuously provided grippy rubber soles for Adidas running shoes like the Ultra Boost. 2.2 Key milestones 1871 - Continental-Caoutchouc- und Gutta-Percha Compagnie is founded in Hanover on October 8 as a joint stock company. Manufacturing at the main factory in Vahrenwalder Street includes soft rubber products, rubberized fabrics and solid tires for carriages and bicycles. 1882 – The rampant horse is adopted as the trademark. 1892 - Continental is the first German company to manufacture pneumatic tires for bicycles. 1898 - Begins production of automobile pneumatic tires without tread pattern in Hanover- Vahrenwald. 1901 - The first Daimler-produced car to be called Mercedes achieves a sensational victory on Continental pneumatics in the Nice-Salon- Nice car