Desenvolvimento e otimização de célula robótica industrial para processo de aplicação de cola

Abstract

Industrial automation has become a strategic tool for optimizing production processes, especially in sectors like the automotive industry, where precision and efficiency are crucial. This work focuses on the optimization of a robotic cell for adhesive application, aiming to reduce robot idle time and increase productivity. The initial cell involved applying adhesive to a single part at a time, which caused periods of inactivity during part changeovers. The implemented solution involved restructuring the cell to allow the robot to apply adhesive alternately to two parts, thereby significantly reducing idle time and increasing process efficiency. The methodology adopted included 3D modeling using Autodesk Inventor, which enabled a detailed visualization of the structural modifications. The new structure was implemented, along with adjustments to the robot’s movement. The cell’s programming was revised to synchronize the operation of both workstations and maximize productivity. The Taguchi method was used to optimize critical process parameters, such as adhesive temperature, robot speed, and adhesive application uniformity. Statistical results showed a significant reduction in cycle time, from 27.5 seconds to 25 seconds, with robot idle time decreasing from 17.5 seconds to just 5 seconds. Production also increased from 130 to 240 parts per hour, representing an 84.6% increase in production capacity. The solution was validated in a controlled environment, where substantial improvements in quality were observed, with a rejection rate of only 1% and 95% application accuracy. These results demonstrate the effectiveness of the proposed improvement, which not only optimized the production process but also proved the technical and economic feasibility of the cell.