Gearbox manufacturer SEAT Componentes needed to automate the unloading of 18,000 machined gears a day at its plant in Spain to ensure part quality. The company successfully integrated 10 collaborative robots from Universal Robots using internal resources. This approach allowed SEAT to maintain expertise in cobot configuration in-house, reducing programming and maintenance costs. The installation was completed without altering the existing factory layout, enabling quick configuration of new applications in less than 1 hour. This automation has led to decreased errors, improved worker safety, and prepared the team for future automation projects.
SEAT is a gearbox manufacturer for Volkswagen Group plants worldwide. The company produces gearboxes from aluminum casting to assembly, focusing on precision and quality. The manual unloading process for gearbox parts was automated with the help of UR cobots, following the success of a previous cobot project in 2015. The cobots were chosen for their easy integration, low footprint, and ability to work alongside operators without safety fencing.
The UR10e collaborative robots were integrated into 10 different machining lines, offering flexibility for model changes. The cobots communicate with the PLC using the PROFINET protocol to unload parts onto trays, minimizing machine stoppages. Autonomous mobile robots transport the trays to a just-in-time warehouse, reducing surplus stock and costs. The cobots ensure that gears are positioned correctly for gearbox assembly, meeting daily production targets.
An additional UR10e cobot was added for training and validation purposes, allowing operators to familiarize themselves with cobot programming. SEAT is self-sufficient in 3D printing gripper fingers for the cobots, ensuring quick spare parts availability and concept testing. Keeping cobot knowledge in-house has enabled SEAT to make faster decisions during stoppages and reduce machine downtime costs.
The intuitive configuration of the cobots and their peripherals, certified through the UR+ platform, has allowed SEAT to implement applications quickly without external integrators. Operators have been freed from manual tasks, allowing them to focus on value-added activities. SEAT now sees cobots as a valuable tool for future automation projects, providing new opportunities for upskilling employees. Overall, the automation project has improved productivity, quality, and profitability, earning approval from the SEAT group.
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