The automotive manufacturer thyssenkrupp Bilstein, a leading global provider of shock absorbers for the automotive industry, is digitizing its shock absorber production in Romania through the use of Panasonic Factory Solutions' TAWERS G4 welding robot system.
The Panasonic TAWERS G4 welding robot system will expand and replace two older welding robot cells that have reached the end of their lifespan after a decade of reliable operation. One of these welding robot cells has been completely upgraded to the G4 system. The dismantled components will be reused as spare parts to extend the lifespan of the second oldest robot cell.
As one of the largest employers in the Romanian county of Sibiu, thyssenkrupp Bilstein manufactures OEM shock absorber assemblies and components for the automotive aftermarket. The Panasonic TAWERS G4 welding robot system enables thyssenkrupp Bilstein to increase speed, flexibility, and user-friendliness in its production line, thus gaining a crucial competitive advantage and achieving its digitization goals.
Panasonic, together with its partner SC TOTAL TEHNIQUES SOLUTIONS SRL, has taken over the complete planning, installation, and ongoing support for this welding robot replacement program.
Higher Processing Speed and Improved Communication
A total of six Panasonic TAWERS welding robot systems are in operation at the plant. The G4 controller features a higher processing speed and optimized communication between the control and the robot.
Compared to previous models, the G4 is smaller due to the newly integrated transformer, saving space and costs without compromising reliability. Additionally, the G4's teach pendant touchscreen simplifies programming in the production line.
Offline System Updates and Reprogramming
The Panasonic TAWERS G4 welding robot system is equipped with offline programming software DTPS, which allows digital remote access to production and system operational data in real-time. This way, technicians can reprogram all or only selected parts of the welding process while the robot continues to operate in production.
Carrying out these activities from outside the workshop offers flexibility and saves time. For example, programming a new welding fixture can take up to three days. With the new technology, it can now be easily tested by uploading CAD data into a digital twin of the cell.
Vincent Londsdale, Key Account Manager at Panasonic Connect, says: 'Automakers are under pressure to automate and streamline their processes while simultaneously reducing costs. Our system has enabled thyssenkrupp to test and simulate innovations outside the workshop in a digital environment before the company has to invest in a new or modified welding process. Since Panasonic can standardize the robot cells, they can be reproduced immediately without additional start-up costs.'
