SOLUTION

Robotic line for producing bowden cable housing

In automotive component manufacturing, where speed and precision are paramount, optimizing space and energy efficiency is critical to gaining a competitive edge. TBP Tovarna bovdenov in plastike, d.o.o., a company specialized in the production of cables, recognized the need to enhance productivity and reduce spatial and energy overhead in the assembly and crimping of cable end terminals. With increased orders, new requirements emerged for upgrading equipment that would enable automated, faster, and more reliable production.   

The project lead, BLUBIT, in collaboration with BOS GRUBAR, developed a compact robotic cell based on a SCARA robotic arm. BOS GRUBAR was responsible for the complete design concept, mechanical engineering, parameterization, system commissioning, and conducting a feasibility study, while BLUBIT handled the electronics, programming, and the advanced user interface, which allows operators to easily set parameters, monitor the assembly process, and effectively track production. The robotic cell enables automated handling of semi-finished products through multiple assembly stages, reducing the need for space, lowering energy consumption, and providing greater precision and repeatability for assembling cables of various lengths.

01 Problem

TBP Tovarna bovdenov in plastike, d.o.o., due to increasing orders and demand, required new equipment that would facilitate higher productivity and automation. The existing production line for cable assembly relied on a large, slower hydraulic machine that occupied considerable space and consumed significant energy. Additionally, the company used numerous smaller devices and fixtures for manual assembly of identical products, which increased the need for labor and further limited production speed and flexibility.

This type of production organization was space-demanding, energy-intensive, and manual labor could not provide the same repeatability and precision as automated solutions. The limitations of existing equipment increased costs and hindered rapid response to rising demand, reducing TBP’s competitiveness in the market.

02 Solution

The robotic cell, developed by BLUBIT and BOS GRUBAR, is based on a SCARA robotic arm that enables fast and precise handling of semi-finished products through key stages of assembly. BOS GRUBAR was responsible for the comprehensive design concept, design, mechanical assembly, system commissioning, and the creation of quality assurance parameters. In addition to the electronic and programming work, BLUBIT contributed the advanced user interface, which allows operators to intuitively set parameters, control the process, and ensure traceability for each product batch.

Technical Details of the Solution

The new robotic line includes the following stages:

Terminal Assembly 1: The terminal is transported via a vibratory feeder, which precisely aligns it into a servo press. A flexible needle positions the terminal, and the SCARA robot inserts the casing with defined force. The robot synchronizes its motion with the servo press, mimicking manual assembly and ensuring 100% reliability, quality, and repeatability of the process.
Assembly of the Complex Silicone Cap: During the assembly of both terminals, the robotic cell also assembles a complex silicone cap, challenging to handle due to its shape. The cap is fed and positioned by a dedicated mechanical sorter, which ensures precise alignment and placement for assembly. 
Terminal Assembly 2: The second terminal is transported via a vibratory feeder to a pneumatic press, which imprints the desired shape on the terminal. The SCARA robot inserts the casing with defined force, ensuring precise fitting and assembly. The entire process is fully automated, ensuring 100% reliability, quality, and repeatability.

At the input stage, the operator manually places the cable casings into fixtures, and the robotic arm handles all subsequent manipulation and assembly operations. The cell optimizes space, increases productivity, and ensures more reliable operations.

03 Results

The implementation of the robotic line for producing bowden cable housing enabled TBP Tovarna bovdenov in plastike, d.o.o., to achieve the following outcomes:

Increased throughput and productivity
Enhanced precision and repeatability of the assembled products,
Reduced energy consumption and operational costs,
Optimized spatial utilization of the production area,
Simplified monitoring and traceability via the advanced user interface.

04 Conclusion

By implementing the new robotic line for producing bowden cable housing, TBP Tovarna bovdenov in plastike, d.o.o., has significantly improved its production capacity, achieving a higher level of product precision while reducing operational costs and optimizing space utilization. The SCARA robotic arm technology and reliable user interface developed by BLUBIT facilitate efficient management and monitoring of the assembly process and allow for rapid adaptation to varying cable lengths.

With this solution, BLUBIT and BOS GRUBAR provide TBP with a competitive market advantage, as the cell meets the stringent standards of the automotive industry, offers flexible adaptability, and supports an optimized manufacturing process tailored to current market needs.