Bulldog Factory Automation in Madison Heights, MI, has been designing and building custom automation systems since 1937. Initially a small service provider for Detroit-area factories, the company grew rapidly in the 1940s, providing production equipment for the war effort.

In 2022, the company was purchased by HG Automation (HGA) and is now a full-service integrator providing turnkey welding and assembly systems for the Detroit Three automakers and Tier 1 suppliers. Today, the company employs a complement of automation experts who have helped the company become a prominent player in the automotive, heavy truck and aerospace sectors, delivering custom-made systems from concept to installation.

Recently, HGA’s design engineers, automation assembly teams, programmers and installation technicians were all brought to bear when a Tier 1 customer needed a turnkey automation system for a new battery electric vehicle component line. HGA was given a condensed timeline in which to design, build, debug and install a five-zone automation system that incorporated part handling, stud and spot welding, and adhesive dispensing for a rear quarter panel assembly.

When the customer’s usual robot supplier was stymied by supply chain issues, HGA turned to Kuka Robotics for help.

The system consists of 86 KR Quantec robots from Kuka. Photo courtesy Kuka

“We had been doing small collaborations with Kuka for some time, but this was our first large, turnkey automation project that we deployed with them,” says Aaron Burke, HGA’s senior business development director.

In addition to a challenging timeline, the project had to meet cost and space requirements. “Essentially, we had to provide a cost-effective, smart solution with the right number of robots and technologies all deployed into as small a package as possible for our customer,” Burke says. “Once we got the customer’s specs, we went through a number of iterations, designing and redesigning the process to get a system that could output the right volume of parts.”

The Assembly Line

The system consists of 86 KR Quantec robots from Kuka. The Quantec series of robots have a slim, modular design for long-reach, high-payload applications, such as welding, machine tending and palletizing. They can carry a maximum payload of 120 to 300 kilograms, and they have a maximum reach of 2,671 to 3,904 millimeters. The robots’ compact design make them ideal for integrating into automation cells, which fit precisely with HGA’s requirements.

In addition, the robots are Kuka’s first to have digital motion modes. These software add-ons ensure optimal robot motion for specific applications. For example, the “path mode” allows for motion with greater accuracy and precision, while the “dynamic mode” increases speed and thus reduces cycle time at bottlenecks on production lines.

The robots handle more than 30 individual parts and generate more than 300 welds. Photo courtesy Kuka

“We needed to meet space, volume and aggressive cycle times, along with other criteria, and Kuka robots allowed us to do that,” says Andrea Conover, HGA manager of program management. “Kuka robots also have great track records of uptime and limited maintenance on the line.”

For the body assembly process, the Quantec robots handle more than 30 individual parts and generate more than 300 welds. In complex synchronized movements, they pick parts, transport them to stations where they are welded together, perform a variety of other spot and stud welds, dispense adhesives, and unload bodies onto rack stations. In addition to robots, the system includes technology for trays, conveyors, trunnions and buffer zones.

Designing and assembling such a complex system was an inherently challenging task that occasionally presented obstacles the HGA team had to overcome. Kuka’s responsiveness was another prime component to the project’s success, according to the team.

“While we were debugging the line, we needed support,” Conover says. “Kuka always responded quickly and was onsite immediately to help us out. That support allowed us to maintain our tight time schedule and good relationship with our customer, so everyone’s end goals were met.”

WorkVisual is a comprehensive tool for configuring, programming, and diagnosing Kuka robots. Photo courtesy Kuka

The ease with which the HGA team was able to program the robots was another feature that figured prominently in getting the line up and running quickly. Programming the robots for the many precision assembly tasks was simplified with Kuka technology. For instance, HGA robot programmer Jared Witt used Kuka’s WorkVisual engineering software to program and configure the robots. The software’s overall ease of use during programming kept the project on schedule, says Witt.

WorkVisual is a comprehensive tool for configuring, programming, and diagnosing Kuka robots. The software integrates all steps of the engineering process into a single interface for a seamless workflow. The suite allows engineers to program and simulate robot motions, test sequences, and optimize performance before deploying robots on the production floor. The software’s intuitive design and extensive functionality significantly reduce setup times and improve overall operational efficiency.

Additionally, the program code is checked for logic in the background while programming steps are being carried out. As a result, errors are caught early on, which allows projects to be implemented quickly and consistently.

“This was my first programming experience with Kuka,” Witt says. “The WorkVisual along with the company’s KR C5 robot controller helped tremendously in reducing the debug time on the system. I was able to write logic out beforehand and work out all the issues prior to commissioning. Other brands don’t have a program that is as comprehensive.”

The project was so successful that HGA plans to continue to work with Kuka.

“This project has been a great experience for us,” Burke says. “Kuka and HGA have developed a solid relationship with one another, and we’ve even started leapfrogging into other areas as a partner in different solutions. That benefits both of our organizations.”

For more information on robots, read these articles:
Kuka Introduces New High-Payload SCARA
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Vision-Guided Robots Process Hydraulic Components