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PurposeTo describe how Jaguar Cars in the UK is making use of a robot‐based intelligent adaptive metal inert gas (MIG) welding process incorporating laser diode measurement of the gap in the joint between the aluminium C‐pillars and the aluminium roof structure of its new XK sports car that is being built in the company's plant in Castle Bromwich, UK.Design/methodology/approachDescribes the sensor technology that is used to guide the robot in order to undertake the MIG welding path.FindingsThe use of MIG welding in this particular application is essential if a perfect surface is to be achieved in a critical area of the car body before the aluminium body shell enters the paint shop. The introduction of MIG welding in this particularly exposed region of the car's body shell has proved to be a challenging experience for a wide range of engineers at jaguar cars in the UK, from manufacturing engineers through to process engineers and metallurgists, and others. The MIG welding of cosmetic aluminium skin panels is the result of considerable research work on the part of Jaguar engineers and the company's suppliers, as well as staff at Warwick University. This work is likely to continue in order to achieve a complete understanding of the entire production process, as well as to reduce cycle times and improve overall product performance, both to the benefit of the manufacturer and the end‐user – the customer.Practical implicationsIt is likely that arising out of development work into new MIG welding techniques and processes, new standards will be used throughout the Ford organization, including other companies that form the Premier Automotive Group. Aston Martin, Land Rover Volvo could all benefit from the technologies developed at Jaguar Cars.Originality/valueThis is the first time that Jaguar Cars has used an ABB 2400‐16 robot in conjunction with a laser diode sensor to measure the true position of a seam prior to welding, allowing the robot's path to be optimised for each individual vehicle. This paper provides a unique insight into the development of a root‐based intelligent adaptive MIG welding process to produce a perfectly finished body shell. |
