Made in Comau
ComauFlex
BIW Plant Strategy
Bangkok, June 23rd, 2016
Xiaowei TAO
Manager, GSD Dept, Body Assembly,Comau China
Made in Comau Property of Comau - Duplication prohibited 2
• Comau General
• What is ComauFlex
• Systems & Solutions
• Products
• Projects with Aluminium Joint
Index
Made in Comau Property of Comau - Duplication prohibited 3
1995 - 97 Comau opens plants
and offices in Germany,
Brazil, Argentina, France
and India
1998 Establishment
of Comau Service
Comau Poland is established
1999 Comau acquires Renault
Automation in France
and Pico in USA, Mexico,
Germany and UK
1973 Several companies
in the Turin area create
COnsorzio MAcchine Utensili
1977 Establishment of Comau
Industriale with
powertrain and body
(welding, assemby and
handling) divisions
1978 Comau S.p.A.
is established
incorporating Comau
Industriale activities
2009 Establishment of
Comau Aerospace
2000 - 03 Comau China, Romania
and Russia are established
2010 Establishment of
Comau Adaptive Solutions
and eComau
2014 Comau Czech and
Turkey are
established
Comau opens office in
Munich (DE)
Comau Mexico
expansion
2013 Comau China in expansion:
3 new sites
Kunshan, Shanghai,
Dalian
2015 Comau Thailand
is established
Comau
São Paulo (BR)
is established
History_Over 40 years of experience in Automotive
Made in Comau Property of Comau - Duplication prohibited
4
Comau in the World
Made in Comau 4
USA
MEXICO
BRAZIL
ARGENTINA
SPAIN
FRANCE
UK
GERMANY
CHINA
THAILAND
RUSSIA
TURKEY
ITALY
POLAND
ROMANIA
CZECH REPUBLIC
INDIA
Property of Comau - Duplication prohibited
Made in Comau Property of Comau - Duplication prohibited 5
Heavy industry Energy Defense
Commercial vehicles
Aerospace Automotive Commercial vehicles
Business Scope
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2012-15 Revenues (MIO €)
2015 Turnover per area (%)
2012 2013 2014 2015
1,950
1,550 1,464 1,450
Key Figures
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• Comau General
• What is ComauFlex
• Systems & Solutions
• Products
• Projects with Aluminium Joint
Index
Made in Comau Property of Comau - Duplication prohibited 8
What is A flexible BIW manufacturing strategy
Traditional Factory Engineered Factory
We deliver the Best Value to our customer
• Logistic Optimized
• Model change simplify
• High Speed Transfer
• Modular Architecture
• Compact footprint
• High density welding
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9
Major Subs
&
Mainlines
Material Staging Zone
Marketplace Part Loading
&
Minor Subs
Part Loading Zone
Material Entry Zone
Quality Zone
ComauFlex Overview Manufacturing Strategy
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10
Maintenance
Production
Material Handling
- Fork-lift
- Tugger
ComauFlex Overview Direct/Indirect Labor
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11
VersaRoll
VersaPallet Fro
nt
Str
uc
ture
an
d R
ea
r F
loo
r
Un
de
rbo
dy F
ram
ing
Fro
nt
Flo
or
an
d s
ub
as
sy
Un
de
rbo
dy R
e-s
po
t
Bo
dy S
ide
Ou
ter
Le
ft
Bo
dy S
ide
In
ne
r L
eft
Up
pe
r B
od
y F
ram
ing
Bo
dy S
ide
Ou
ter
Rig
ht
Fra
min
g R
e-s
po
t
Fro
nt
an
d R
ea
r R
ail
s R
/L
Bo
dy S
ide
In
ne
r R
igh
t
ASSEMBLY ZONE
MATERIAL ZONE
ComauFlex Overview Example
Made in Comau Property of Comau - Duplication prohibited
Floor Plates BRIC Legs
Shipping Modules
ComauFlex Overview Example
12
Integrated Lines
Made in Comau Property of Comau - Duplication prohibited
Welding Guns
Vision Systems
Break-Away
Pallet Transfers
Pallet Tooling
Logistics-SPD
Line Feeding Devices Roller Heming
AGC
APC
13
How to be ComauFlex Modular Strategy
VersaPallet
OpenGate VersaRoll
Made in Comau Property of Comau - Duplication prohibited 14
• Comau General
• What is ComauFlex
• Systems & Solutions
• Products
• Projects with Aluminium Joint
Index
Made in Comau Property of Comau - Duplication prohibited 15
VersaRoll System
Made in Comau Property of Comau - Duplication prohibited 16
VersaRoll System
For Return
All carbinet upstairs
Simplify cable/wiring connection
Tool tray
Space on floor to be extended
Made in Comau Property of Comau - Duplication prohibited 17
VersaPallet System
Made in Comau Property of Comau - Duplication prohibited 18
VersaPallet System
For Return
All carbinet upstairs
Simplify cable/wiring connection
High Desity
Robot
Welding
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Opengate System
Made in Comau Property of Comau - Duplication prohibited 20
Opengate System
Open RoboGate ®
up to (6) Models
Key Features:
Up to (18) Welding Robots
Integrated solution for cabinets
Scalable investment
Up to (6) dedicated gates
Since 2010,
70 stations install in China
With 185 gates
Phase 1 Phase 2
Phase 3 Phase 4 Phase 5
Made in Comau Property of Comau - Duplication prohibited 21
• Comau General
• What is Comau FLEX
• Systems & Solutions
• Products
• Projects with Aluminium Joint
Index
Made in Comau Property of Comau - Duplication prohibited 22
Geo Pallet with Power Roller Bed
For Geo For Respot For Facility
• NO Air Supply
• NO Shim Adjustment
• NO Wiring
• NO Piping
• ±0.1mm Repeatability in X/Y/Z
• 6.0s for horizontal transfer
• 1.5s for pallet up
• 1.5s for pallet down
TOLERANCE X ± 0.1mm
TOLERANCE Y ± 0.1mm
TOLERANCE Z ± 0.0mm(touch)
TOLERANCE X ± 0.5mm
TOLERANCE Y ± 0.3mm
TOLERANCE Z ± 0.5mm
• 6.0s for horizontal transfer • 6.0s for horizontal transfer
Made in Comau Property of Comau - Duplication prohibited 23
Compact Gun Family_For Steel
+
+
• NO casting component
• Al Alloy Body 7075
• Common servo motor and transformer
• Weight 65~90kg
Force up to 440 daN
Force up to 700 daN
• Al Alloy Arm 7075
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Compact Gun Family_For Steel
Robot Payload
90~110kg
• Less Space
• More Faster of movement
• Smaller Robot
• High Desity
Gun Weight
65~90kg
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Compact Gun Family_For Aluminium Ducker Worldwide Aluminum in cars, 2015
Aluminum Body and Closure
(% of Volume)
Mark
et
Sh
are
(%
of
pie
ces)
2015 Ducker Worldwide
Automaker Survey
Compact High Force
• Weight 110 ~ 130 kg
• MFDC Transformer 255 KVA at 50% DC
• Welding Force X-Gun 600 daN
C-Gun 704 daN
• Actuator (Inverted roller screw)
X-Gun 1764 daN
C-Gun 704 daN
• Software equalizing (COMAU, KUKA, ABB, FANUC)
• External load washer with amplifier for force feedback
Made in Comau Property of Comau - Duplication prohibited 26
Compact Gun Family_For Aluminium
Real Applications Test In House
Result Achieved:
Tip dressing each 24 spots – Electrode life up to 2600 spots
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RecogoniSense System(Vision)
RAIO = RecogniSense All-In-One
3D Camera Processer
LED
Light
Recognition process time: < 300 ms
Rack position: +/- 75 mm X, Y, Z
+/- 5° Rx, Ry, Rz
System Accuracy: +/- 0.5 mm X, Y, Z
VOV(Volume of View): Min 50mm x 50mm x 25mm
Max 2400mm x 1200mm x 600mm
Resolution X/Y/Z: +/- 1.0 mm @ Max VOV
+/- 0.1 mm @ Min VOV
Resolution Rx/Ry: +/- 0.2 degrees
Resolution Rz: +/- 0.1 degrees
Key Features
Made in Comau Property of Comau - Duplication prohibited 28
RecogoniSense System(Vision)
Traditional + + +
Rack Operator Centering Tooling Robot+Gripper
With RAIO
Rack
+
Robot+Gripper+RAIO
>>>>>>>> NO operator
>>>>>>>> NO centering
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RecogoniSense System(Vision)
Bodyside Outer Loading
From normal rack
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• Comau General
• What is ComauFlex
• Systems & Solutions
• Products
• Projects with Aluminium Joint
Index
Made in Comau Property of Comau - Duplication prohibited 31
Projects with Aluminium Joint in China
Customer Plant Model Scope Production Capacity Joint Technology
1 Jinqiao China O11 Framing Inner;Framing
Outer;Sunroof;Respot Line 10JPH
RSW/SPR/FDS/Al Laser
Brazing/Al Hemming
2 Changshu China X261 UB and UB sub 16.4JPH SPR
3 Hangzhou China CD539 Hood 20JPH SPR
4 South Plant China E15/E16 Hood/Decklid 27JPH Clinch/Al Hemming
5 SGM South Plant China A10 Hood 15JPH Clinch/Al Hemming
Made in Comau Property of Comau - Duplication prohibited 32
Projects with Aluminium Joint in China
1 2 3
4 5 SPR
FDS
Made in Comau
Via Rivalta, 30 - 10095 Grugliasco - Torino ITALY - www.comau.com
Thanks
For your Attention