What were the challenges to be solved and what specific benefits were achieved?

The demand of a clear identification of the components and the corresponding parameter allocation particularly rises in large-scale production companies. There are different possibilities of identification. For example, the components can be labelled directly. Another option is to provide the workpiece carrier with a memory chip which enables their allocation.

The complex robot system with the intelligent shuttle system reduces the error rate and allows to use a chaotic production system. Due to the increased productivity LTI can expand its competitiveness.

"Together we created a system that is the only one of its kind anywhere in the world. Without the new robot system we could not handle such high volumes. It enables us to process the many component variants without major retooling."
Kai Kallsen, Welding Supervisor, LTI-Metalltechnik GmbH

How can the Industrie 4.0 approach be described?

The complex, chained system by Cloos has an intelligent automatic shuttle system. Via a magnetic code on the jig, the shuttle can identify the correct welding station for the component during loading. The welding robot also identifies from the jig which welding program to use for the component.

What could be achieved?

Due to the use of the chaotic production system, the number of parts and the order per series are irrelevant and production-related waiting times are avoided. Thus LTI can process a multitude of component variants without the need to convert every time. In total, the company is now able to produce higher quantities at shorter production times. At the same time the error rate is reduced considerably. An additional benefit of the system: the jigs' coding system allows seamless documentation, making it possible to track the particular robot, time and welding program used for every single weld.

What measures have been taken to achieve the solution?

CLOOS and LTI-Metalltechnik implemented the project together. Different departments were involved in the development of the robot system.

What can others learn from it?

The employees of the manufacturer CLOOS worked very close together with the employees of LTI-Metalltechnik. Thanks to the open and flexible cooperation between the different departments in both companies many ideas and suggestions could be developed. An important basis for the successful planning and realisation of the project.