The following is an excerpt from a summary report from Ford Vehicle Operations
Summary
As a pilot project in preparation
for the B-Car project, the full service suppliers Kuka, Valiant/Steelweld, and ComauPICO committed to design and fully (including
calibration) offline program (OLP) nearly 100 robots for the CD132 vehicle at Genk. Several tests, especially involving the
DynaCal calibration tool, have been conducted by group staff and the Genk plant maintenance department, but CD132 is the first production
program to utilize the OLP technology to achieve a "no manual touch up" level of accuracy. With the help of plant maintenance
staff, and Dynalog, the work was completed for all robots within two days, and accuracy checks (visual against a prototype panel)
looked good. To quantify the accuracy, a test program was created and downloaded to one robot, and the measured accuracy was
less than 1mm, which achieved the desired goal. Better accuracy could be achieved through better design and repeatability of
the End of Arm Tool. Additional maintenance related benefits were identified by the Genk plant staff, resulting in a project
to calibrate all the V184 body shop robots as well.