Bulldog Factory Automation, established in 1937, has a long history of providing customized factory solutions to enhance production efficiency. Originally a small service provider for Detroit-area factories, Bulldog was acquired by HG Automation (HGA) and has since become a full-service integrator, offering turnkey solutions for body-in-white welding at major OEM automaker and Tier 1 supplier plants in Detroit. The company is a key player in the automotive, heavy-truck, and aerospace sectors, delivering custom-made systems from concept to installation.
Recently, HGA’s team, including development and design engineers, automation assembly experts, programmers, and installation technicians, was tasked with creating a turnkey automation system for a new battery electric vehicle (BEV) component line. Faced with a tight timeline, HGA was required to design, build, debug, and install a five-zone automation system incorporating part handling, stud spot welding, and adhesive dispensing for a BEV rear quarter assembly. When the customer’s usual robot supplier encountered supply-chain challenges, HGA turned to KUKA Robotics for assistance.
“We had collaborated with KUKA on smaller projects before, but this was our first large-scale, turnkey automation deployment with them,” said Aaron Burke, HGA’s Senior Business Development Director. In addition to the challenging timeline, the project needed to address cost and space constraints. “We had to deliver a cost-effective, smart solution with the right number of robots and technologies, all within a compact package for our customer,” explained Burke. “We went through several design iterations to develop a system that could achieve the required production volume.”
The solution involved deploying 86 KR Quantec robots from KUKA. The KR Quantec series features versatile, six-axis robots with payloads ranging from 120 to 300 kg, offering manufacturers flexibility in handling various production applications. These robots also adapt well to cost-effective cell planning, which met HGA’s needs. “We needed to meet space, volume, and cycle time requirements, and KUKA robots enabled us to achieve those goals,” said Andrea Conover, HGA’s Manager of Program Management and project manager. “KUKA robots are known for their reliability and minimal maintenance requirements.”
For the body assembly process, the Quantec robots manage over 30 individual parts and execute more than 300 welds. They perform synchronized movements to pick parts, transport them to welding stations, apply adhesives, and unload the assembled bodies onto rack stations. The system also includes technology for trays, conveyors, trunnions, and buffer zones.
Designing and assembling such a complex system presented challenges, but KUKA’s responsiveness was crucial to the project’s success. “KUKA was always quick to respond and provide onsite support, helping us stay on schedule and maintain a good relationship with our customer,” Conover noted. Another key factor in the project’s success was the ease of programming the robots. HGA’s robot programmer, Jared Witt, utilized KUKA’s WorkVisual engineering suite to program and configure the KR Quantecs. The software’s user-friendly interface and extensive functionality helped keep the project on track.
KUKA.WorkVisual is a comprehensive tool that integrates all steps of the engineering process, from configuring and programming to diagnosing robots. It allows users to simulate robot motions, test sequences, and optimize performance before deployment. The software’s intuitive design and advanced features significantly reduce setup times and enhance operational efficiency. “This was my first time programming with KUKA,” Witt said. “The WorkVisual software, along with the KR C5 robot controller, greatly reduced debug time and helped us address issues before commissioning.”
The successful completion of this project within the challenging timeline, along with the strong technical support provided by KUKA, has strengthened the partnership between HGA and KUKA for future collaborations. “This project has been a valuable experience for us,” Burke said. “Our relationship with KUKA has grown, and we’re now exploring new areas of collaboration that benefit both of our organizations.”
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