Car transfer unit from Ewellix

Application Technology

Automotive assembly plant overview

Body-in-white applications

Flexible production line needs

Customer case on application

CTU

Gripper

Jig-geoset

Ewellix offer and value proposition

CTU

Grippers and Jiggeoset

Customer support tools

Available tools to support customers choosing the right

Ewellix product

Application technology

Automotive assembly plant overview

Body-in-white gripper

A gripper is a device which enables the holding of an object to be manipulated. Just like a hand, a gripper enables holding, tightening, handling and releasing of an object. A gripper can be attached to a robot or it can be part of a fixed automation system. Normally grippers are pneumatic operated but there’s an electrification trend ongoing.

Body-in-white jig – geoset

A Jig / Fixture is a device that holds, supports or is placed on a part to be machined or welded. It is a production tool made so that it not only locates and holds the work piece but also guides the tool as the operation is performed.

Body-in-white car chassis support system

What are the function of a CTU?

CTU can be rapidly and efficiently reconfigured to transport different car-models on a single assembly line. In comparison with the use of conventional assembly equipment and tooling, the use of these products reduce the amount of re-programming and commissioning needed to transition between the production of different models.

Why do car makers need a flexible production line?

Car models are refreshed ~ every 2 to 3 years
More car models are required to reach a wider market and to maintain sales (continuous erosion of car sales per each model)
Each plant must be able to produce more models
The automotive assembly line of the future must be conceived differently (Small & Smart)
OEMs must be able to react quickly to market fluctuations (demand for each model, or shift of sales between cars, SUVs, trucks and EV)
Cost reduction in manufacturing / assembly
Space reduction from Fixture system
Quick reset (seconds) between models manufactured on one assembly line
CTU system designed for 10 years of service life, across multiple platforms and models

Customer case on application

Car Transfer Unit

Customer issue

To replace the fixture solution or turn table Pin with flexible electrical solution fitting perfectly in place.

The solution

The CTU concept and design started in 2012 with R&D center and more than 500 pcs of CTU are equipped at Body-in-White globally since 2012.

Value for customer

▪ No need for CTU re-programming and commissioning when changing car model

▪ Less investment for multiple car models or platforms manufactured in one plant

▪ Less storage space for assembly equipment and tooling for each model

▪ Quicker and more economical re-tooling for model refresh and new platform

Grippers (End-effector)

Customer issue

To replace pneumatic or fixture solution with flexible electrical solution fitting perfectly in place.

The solution

The CLSM-92 concept and design started in 2014 with R&D center and more than 7.000 pcs of CLSM-92 are equipped on Robot for Flexible Gripper globally since 2014.

Value for customer

▪ No need for Gripper(End-effector) system re-programming and commissioning when changing car model

▪ Less investment for multiple car models or platforms manufactured in one plant

▪ Less storage space for assembly equipment and tooling for each model

▪ Quicker and more economical re-tooling for model refresh and new platform

JIG (Geo-set)

Customer issue

To replace the fixture solution with flexible electrical solution fitting perfectly in place.

The solution

The CLSM-92 concept and design started in 2014 with R&D center and more than 3.000 pcs of CLSM-92 are equipped on Pallet for JIG(Geo-set) globally since 2014.

Value for customer

▪ No need for JIG(Geo-set) re-programming and commissioning when changing car model

▪ Less investment for multiple car models or platforms manufactured in one plant

▪ Less storage space for assembly equipment and tooling for each model

▪ Quicker and more economical re-tooling for model refresh and new platform

3. Product odder and value proposition

Car Transfer Unit – CTU

The need of handling different types of car chassis Body in White (BIW) on the same line requires a flexible system setup that allows a quick resetting with precise positioning.

The optional linear modules for vertical axis provides the high speed by precision ball screw and the integrated dampening system protects the telescopic pillar from mechanical shocks during the loading and unloading phases, ensuring high reliability and longer lifetime in operation.

The usage of customer-defined servo motors allows for easier integration into the control network, reducing the commissioning time of the transfer unit.

Car transfer unit solution – Features and benefits

Design for Automotive Industry
More than hundreds units have been sold to Automotive production line for many different applications
Steel cover and Inner mounted cableveyor for antispatter
Integrated motor, controller, cables, mechanical brake and shock absorber
High positioning accuracy and repeatability due to Precision ball screw
Precise alignment and secure fastening of attachments with threads and pin hole in carriage and bottom plate
Compact design 1050 x 560 x 694mm (stroke 600 / 240 / 200mm)
Various size for load capacity
Multi axes options

Ewellix H(S)CTU & LCTU – Multi axes unit

LCTU is equipped linear module for Z-axis and provided high speed and high dynamic load capacity for lifting BIW. Normally LCTU is using for welding process at BIW shuttle line and located outside of shuttle.

HCTU is equipped telescopic pillar for Z-axis and provided low retracted length and high static load capacity for BIW assembly. Normally HCTU is using for welding process at BIW pallet and located on the moving pallet(under BIW).

LCTU system description

HLSM-380 – Linear Module

HLSM-300 – Linear Module

HLSM-200 – Linear Module

H(S)CTU system description

HLSM-340 – Linear Module

HLSM-240 – Linear Module

HLSM-300 – Linear Module

HLSM-290 – Linear Module

CPSM – 2section – Telescopic Pillar

CPSM – 3section – Telescopic Pillar

CTU Controller dimensions

CTU Controller – features and options

CTU Controller – connection diagram

Grippers (End effector)

In order to cover a broader market and grow sales, manufacturers need to design more and more new models as the demand grows.

This means that factories must produce these on assembly lines in a cost-saving manner, whereby switching quickly from one model to another on a production line is done seamlessly.

At Ewellix, we offer robust linear modules for flexible end effector systems suitable for robots that have heavy load capacity, repeatability and durability

Jig(Geo-set)

In order to cover a broader market and grow sales, manufacturers need to design more and more new models as the demand grows.

This means that factories must produce these on assembly lines in a cost-saving manner, whereby switching quickly from one model to another on a production line is done seamlessly.

Ewellix can provide robust linear modules for flexible JIG (Geo set) systems with heavy load capacity, repeatability and longer working life

CLSM-92 features and benefits

Design for Automation & Automotive Industry
More than thousands units have been sold
Compact design: 92 x 60 mm
High load capacity (Static 13 300N, Dynamic 9 500N)
High positioning accuracy and repeatability due to Precision ball screw
Easy maintenance provided by One-point lubrication from both carriage sides
Stainless Steel cover for anti-spatter
Precise alignment and secure fastening of attachments with threads and pin hole in carriage and bottom plate
External mechanical brake option