Optimization of the cycle time of robotics resistance spot welding for automotive applications

TLDR

Resistance spot welding is a common automotive manufacturing process, often performed by robots, and improving its efficiency can reduce costs, environmental impact, and increase productivity. The study aims to optimize robot movement and sequencing in a four‑robot spot‑welding line to reduce cycle time. Using the DELMIA‑V5 simulation platform, the authors modeled robot trajectories, holds, and inter‑robot coordination to derive an optimal welding sequence. The optimized sequence cut the 532‑second cycle by 68 s (12.7 %), demonstrating that DELMIA‑V5 can generate time‑saving, higher‑quality welding algorithms.

Abstract

Abstract In the automobile manufacturing industry, resistance spot welding (RSW) is widely used, especially to build the car's body. The RSW is a standard and wide‐ranging joining technique in several assembling ventures, showing a wide range of possibilities for a competent procedure. Robots are commonly used for spot welding in various industrial applications. After completing assembling design, interest increases to improve the designed processes, cost‐reduction, environmental impact, and increase time productivity when all is said to be done. In this paper, the robot movement between two welding points, a path followed while spotting, gripping and payload‐carrying activities, numbers of holds, moves, and a possibility to enhance interaction between four Robots were analyzed using an offline Robot simulation software “ DELMIA ‐V5.” The body shop assembly line of the SML ISUZU plant has four robots that perform about 209 welding spots in 532 s. The optimal model reduced the whole welding cycle time by 68 s, and after modification and proper sequencing, a12.7% reduction in cycle time was achieved. The offline Robot simulation software “ DELMIA ‐V5” has good potential to produce optimal algorithms while saving precious time. It enables an organization to promote higher quality and to encourage meaningful creativity by reducing design flaws.