May 29, Valu Flex TM BIW Geo System A New Concept of Geometry Tooling for Body-In-White Applications

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1 Intelligent Factory of the Future the 2008 AI/GI/GRV/IS Conference May 29, 2008 Windsor, Ontario Valu Flex TM BIW Geo System A New Concept of Geometry Tooling for Body-In-White Applications Dominic Baulier Valiant Machine & Tool Inc.

2 Evolution of Robot Performance and Price Over the Last Two Decades... es... Evolution of Robot Performance and Price has driven traditional body shop toward a very lean configuration. n.

3 Impact on geometry station for small and medium size BIW sub-assemblies Broad generalization of robot inboard geometry Dedicated Geo end effector Modular Geo end effector Courtesy of Spider-Grip TM Courtesy of Finuchem TM

4 Impact on geometry station for large BIW assemblies: body framer Body framers have evolved from just flexible machine, to systems that become more flexible, modular, accurate standard, with integrated mating, thanks to a more extensive as well intensive use of robots. New load capacity do not only allow the same robot to carry a geometry tool, but in the same time its associated fastening devices, to achieve fully integrated tasks from tool selection, part loading, geometry setting, up to final fastening operation.

5 Valu-Flex GEO-POD TM GEO-POD TM Dovetail Wedge-lock system +/- 120 dan Challenge #1 Design a generic tool structure with the following characteristics: High rigidity to minimize geometric dispersion from part to part Sufficient height to accommodate most vehicles Low weight to allow easy robot handling Deflection versus force applied at very end of Geo-Pod arm Real working zone in normal operation 0.40 ( +/ dan applied in vertical) direction) Force (dan) Stiffness chart Deflection (mm) Hysteresis +/- 4 microns

6 Valu-Flex GEO-DOCK TM GEO-DOCK TM Selfsealing pneumatic coupling e-coupling Challenge #2 Design a docking station with the following characteristics: Capability of docking with a final approach angle within a 90-degree cone, including utilities High accuracy and positioning repeatability, measured even at the far end of the Geo-Pod High rigidity in locking mechanism to ensure pod remains stationary under load Compliance under excessive load after engagement of locking mechanism to ensure pod and docking station are not damaged in case of robot crash Cone locators and latch Deviation (micron) Geo-Pod / Geo-dock positionning repeatability on 64 consecutive dockings (Results compensated for ambient temperature variation) Docking # X Dispersion (mm), 6 Sigma = mm Y Dispersion (mm), 6 Sigma = mm Z Dispersion (mm), 6 Sigma = mm

7 Valu-Flex Dovetail Wedge Lock System Challenge #3 Design a compact coupling mechanism between the pod and the robot wrist with the following characteristics: Strong enough to lift and carry the pod Thin enough to allow the welding gun to perform its functions without hindrance Vertical compliance when docked by robot, to ensure robot does not fight against rigidly grounded pod.

8 Valu-Flex Integrated Mating : Load locate and weld in Geo-station Challenge # 4 Allow loading of large part in Geo-station by cooperation of two or more Geo-Pods carried by separate robots controlled by same CPU, and insure: optimal and stable trajectories, without robots fighting each other through the carried part. safe robot control even in case of incidental event. redundant protection through tooling in case of robot controller failure.

9 TM Valu Flex Concept applied to small units: Fender setting Valu-Flex concept applied to fender setting Dedicated traditional fender setting

10 TM Valu Flex Concept applied to Large unit: Body Framer

11 TM One Model Valu Flex framing system GEO-DOCK TM and GEO-POD TM The Valu Flex TM concept applied to Framing system is completely expandable from a one-model, to up to a six-model framing system. No flexibility entry ticket required at introduction of first part. Dedicated welding robot

12 TM Two-Model Valu Flex Framing System Two GEO- DOCKs TM per robot are added to system Expanding the one-model Valu Flex TM Framing system to a two-model system will require: 8 new standard Geo-Pods TM 16 new standard Geo-Docks TM Minimal incremental investment for introduction of second to third additional model. Minimal investment in dedicated tooling.

13 TM Three to Six-Model Valu Flex Framing System Four material handling robots added to two-model system Storage racks capable of storing GEO- PODs TM for up to 6-models Expanding the two/three-model Valu Flex TM Framing system to a six-model system will require: A set of Geo-Pod TM storage racks 4 material handling robots still keeping dedicated tooling at minimal level.

14 THANK-YOU! Valiant Machine & Tool Inc. Valiant Machine & Tool Inc Anchor Driv e Windsor Ontario Canada N8N 5A8 Phone Fax U.S. Phone

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