Robots shouldering more load

The use of robots to assist human employees in the assembly of vehicles is not new at Audi. For many years, the company has used robots to assist in difficult, dangerous or repetitive tasks, creating a more efficient, safer and pleasant environment of the human workers.

Now, a new robot ‘colleague’ has been introduced in the assembly of Audi A4/A5 models, and what’s more, people and robots now work there side by side without a protective fence. With this human- robot cooperation (HRC), the smart factory comes closer to reality at the Audi plant in Ingolstadt. 

‘Adhesive application with robot assistance’, abbreviated from the German as KLARA, provides support with the installation of roofs made of carbon-fibre reinforced polymer (CFRP) in the new Audi RS 5 Coupe 

So for the first time, Audi is using an HRC light robot in its main plant for applying adhesive in final assembly. Similar robots are already integrated into production in the body shops in Ingolstadt and Brussels as well as in engine assembly in Győr. 

As the first step, an employee places the carbon-fibre reinforced polymer roof on a rotary table and tilts it. The application of adhesive is triggered by pressing and holding a button. An illuminated ring indicates when KLARA has precisely applied adhesive over a length of more than five metres. The robot then signals that the roof is ready for installation. The employee takes the roof with the aid of a handling device and installs it in the car. The CFRP roof is optional equipment in the new Audi RS 5 Coupe (due in Australia later this year) and is significantly larger than comparable roof systems. A person would therefore not be able to apply the adhesive as reliably and accurately as KLARA.
Unlike conventional robots, KLARA does not require a protective fence, which means that the working spaces of human and machine blend into one. This saves considerable space at the assembly line and allows HRC to be integrated into the production line. With human-robot co-operation like this, employee safety has top priority at Audi. The employee is in control, initiates the application of adhesive and can halt the process at any time. Sensors in the robot arm recognise when a human is touched and automatically stop any movement in the case of danger.