Paving the way for digitalization of the damper shopfloor

Increasing speed, flexibility and operator-friendliness of a thyssenkrupp Bilstein production line via retrofit upgrade to the new Panasonic TAWERS G4 Welding Robot System.

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Client: thyssenkrupp Bilstein

Location: Sibiu, Romania

Product(s) supplied: TAWERS WG4 Arc welding system

Challenge

After more than a decade of reliable operations, two welding robot cells were about to face end-of-life. ThyssenKrupp’s team on site, with the support of Panasonic and its partner, was charged with the task to develop a retrofit concept for the automotive welding robot cells in a financially competitive scenario.

Solution

The first welding robot cell has been upgraded to the G4 Welding Robot System– and the de-installed components will function as a source for spare parts for the second oldest robot cell. The upgrade becomes even more efficient with the DTPS offline programming software installed two years ago and a coming iWNB installation, enabling remote digital access to real time production and system operating data.

"To keep the line running, fast reaction times are everything. Sometimes we need instant access to a capable consultant, sometimes spare parts as soon as possible, sometimes a maintenance team available on site in an instance. Panasonic has shown to be fully committed to our support."

The leading automotive supplier maintains 3 plants in Transylvania, the central region in Romania. Near the city Sibiu, more than 1290 employees manufacture OEM damper assemblies, damper assemblies for the aftermarket sector and damper components. The company is one of the biggest employers in the wider region and keen to defend that position. Digitalization plays an integral part in staying ahead of the competition and in achieving the plants’ goals. The increased speed, flexibility and usability of the TAWERS G4, the newest robot system from Panasonic, will become an integral part of the strategy.

In total 6 TAWERS equipped robot welding cells from Panasonic are operating in the plant manufacturing for the aftermarket sector. With the first one installed in 2013 and the latest in 2023. The first ever installed cell has now been upgraded to TAWERS G4.

Reliability – also when it comes to supporting change

Madalin Cirjan is welding manufacturing engineer in Sibiu and part of the team responsible for the process optimization. “Panasonic helped us to find an intelligent and cost-efficient way of retrofitting”, he states. The scope of the first step is replacing the oldest cell, the second oldest is about to be included in an upgrade very soon – but until then, we will utilize parts from cell one as spare parts and therefore increasing the lifespan of cell two and save costs.

Panasonic has always been a reliable partner for thyssenkrupp Bilstein – from planning to installation and after-sales support. In cooperation with SC TOTAL TEHNIQUES SOLUTIONS SRL, a local partner of Panasonic Robot & Welding.

Next to the clever reuse, the new system provides a lot of advantages. The controller processing speed has increased and the communication between controller and robot has been optimised. Additional features like the new generation of teach pendant with touch screen function has also turned out to be very useful.

"It’s the small things, such as during “teach in” programming in the production line, e.g giving programs a name or moving them around, that prolong programming times and can be sometimes annoying. With the touch screen function of the new G4 teach pendant all of that is history.”"

The newly integrated transformer also saves space and costs – still providing the same level of reliability when it comes to transforming to three phase AC 200V.

Madalin emphasizes: “The faster processing time and the touchscreen controller are clearly the main advantages from our side. Also, that the system is more compact due to the newly integrated transformer is positive, even though space saving in our plant is not a big issue, it is still not irrelevant.”

Marking a Milestone – on a longer journey

The installation of the G4 robot system is marking an important milestone of thyssenkrupp Bilstein Sibiu digitalization journey in the factory. “But the journey has not started just now – and it is not at an end”, as Florin Dobrita, Head of Manufacturing and Process Planning at the plant, explains. Further plans for improvement are already existing.

Improving the digital impact on the shopfloor already started in 2022: The first step was the change to Panasonic’s DTPS software, installed in 2022. With the offline programming of the welding process, the production itself is not affected. Florin Dobrita stresses the advantages for the factory: “We can reprogram all parts, or just some parts, while the robot is still running. For a new welding, up to 3 days programming is not uncommon – carrying this out outside the shopfloor saves a lot of time.” Evaluation for collisions or implementing a new welding fixture can easily be tested by uploading our CAD data into the digital twin of the cell.

Vincent Lonsdale stresses: “Before you spend one cent on the prototyping process, you can test and simulate whatever modifications you wish to make offline, in a digital environment. All of this is done outside of the shopfloor – no dust, no heat, no noise. Full focus on the new or modified program, welding fixture or process, without shopfloor production distractions.”

Another advantage Christian Kather, the Technical Training Manager from Panasonic Connect, points out, is Panasonic’s capability to align the cells, even though of different robot types, to one standard – which again allows for more flexibility: “The customer asked us to ensure that the copy function of programs is working from each cell. Which can not only save time, but in case the original indicated robot cell is occupied with another project, there are now 5 more that can be used instantly with almost no additional ramp-up efforts.”

Paving the way for digitalization of the damper shopfloor

Challenge

Solution

Reliability – also when it comes to supporting change

Marking a Milestone – on a longer journey

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