Robotic cell for body-shop subassembly welding
Turnkey robotic welding cell for a tier-1 automotive supplier, from EPLAN design through FAT and SAT on the customer floor.
- Delivery geography
- Türkiye
- Variants in scope
- 1 cell, 3 part families
- Program duration
- 9 months, concept to SAT
- Responsibility level
- Turnkey
- Standards applied
- IEC 60204-1 · ISO 10218-2 · EN ISO 13849-1
What the delivered system actually does.
A body-shop cell joins pressed steel subassemblies into the structure of a vehicle. The robot does the welding, but almost everything that determines whether the cell works is around it: the fixtures that hold the parts, the safety that lets people near it, and the controls that decide when a part may move on.
What was handed over is a working cell, not a robot. EPLAN design, the control and safety architecture, the panels, the programming, and then acceptance twice — factory acceptance in Bursa against the design, and site acceptance on the customer floor against their real parts and their real takt.
For a tier-1 supplier the value of turnkey here is accountability. One party is answerable for the weld quality, the cycle time and the safety case, so a problem at handover is investigated rather than argued over.
A tier-1 supplier won a new body-in-white subassembly and had no cell to build it on. Cycle time, weld sequence and part variance all had to be locked before the OEM ramp date, and the cell had to slot into an existing hall with fixed media and conveyor interfaces.
STARTING CONDITIONProduct data and a target cycle time existed; the line concept, fixturing and controls did not.
- Part CAD and weld specification from the OEM release
- Target cycle time and annual volume forecast
- Hall layout with media and conveyor interface points
- Customer PLC and safety standards handbook
- Cell concept and robot simulation against the target cycle
- EPLAN electrical design and control panel build in-house
- PLC, HMI and safety programming to customer standards
- Fixture procurement and mechanical integration
- FAT with customer parts at GANI, then SAT and ramp support on site
- As-built documentation and operator training
What the program delivers.
- FAT passed with customer-supplied parts before shipment
- SAT completed inside the planned installation window
- Cell released for the OEM ramp with signed acceptance protocol
- Spare parts list and drawings handed over from build records
