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FORD OTOSAN

Body & Assembly Shops

Equipment Information Document

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responsibility is accepted by Ford Otomotiv San A.Ş. or its subsidiaries or

affiliates either jointly or severally, for any loss or damage arising in any way

from its use.

Sale Package

The package to be sold is composed of:

• 3 pairs of symmetrical full-automated vehicle bodyside lines

• 2 different full-automated complete vehicle body framing lines,

• 1 semi-automated vehicle underbody line,

• Manual weld guns,

• Several material handling equipments and conveyors (Body &

Assembly)

• Miscellaneous/unique equipments.

Contents

1. Body Shop

1.1. Framing 1

1.2. Framing 2

1.3. Bodyside 1 (Left)

1.4. Bodyside 1 (Right)





1.9. Underbody

1.10. Manual Weld Guns

1.11. Miscellaneous/Unique equipments

2. Assembly Shop

2.1. Skillet Conveyors

2.2. EMS Carriers (for windscreen assembly)

2.3. Body Overhead Conveyor Systems

2.4. Engine Assembly And Mounting Dollies

2.5. Engine Assembly Dollies

2.6. Fluid Filling Stations

2.7. End Of Line Lift and Conveyor

1. BODY SHOP

1.1. Framing 1

Lay-Out

Specifications

Number of stations 17

Number of robots 33

Line capacity (actual) 31 veh/hour

Conveyor type Independent power roller bed conveyor system

Process summary • Spot welding of underbody, right&left bodysides and roof structure

(geometry and respot)

• Automated underbody floor drilling operations

• Additional manual MAG welding operations in closed cabinet.

1.1. Framing 1

Visuals

1.1. Framing 1

Major Equipments

Item Model Count

Comau Robot See next page for details 33

Robotic Spot Weld Gun Sciaky / ARO 40

Robotic Sealer Unit SCA 3

Tool Changer Walther-Präzision 32

Electrode Changing Machine (Elektrodmak) - 11

Electrical tip dresseer AEG 32

Turn Table - 1

MAG Welding Machine - 7

1.1. Framing 1

Robot Details

1.2. Framing 2

Lay-Out

Specifications


Number of robots 11


Conveyor type Independent power roller bed conveyor system

Process summary Spot welding of underbody, right&left bodysides and roof structure

(geometry and respot)

1.2. Framing 2

Visuals

1.2. Framing 2

Major Equipments

Item Model Count

ABB Robot See next page for details 10


Robotic Spot Weld Gun Nimak 12



Lift Turn Table - 1

MAG Welding Machine - 7

1.2. Framing 2

Robot Details

1.3. Bodyside 1 (left)

Lay-Out

Specifications


Number of robots 11

Line capacity (actual) 30 parts/hour

Conveyor type Lift shuttle in linked lines

Process summary Spot welding of left bodyside inner and outer panels (geometry and

respot)

Visuals


Major Equipments


Item Model Count


Robotic Spot Weld Gun Sciaky 12





Robot Details


Sealer Robot Details

1.4. Bodyside 1 (right)

Lay-Out

Specifications


Number of robots 11



Process summary Spot welding of right bodyside inner and outer panels (geometry and

respot)

Visuals


Major Equipments

Item Model Count


Robotic Spot Weld Gun Sciaky 12






Robot Details




Lay-Out

Specifications


Number of robots 6




respot)

Visuals


Major Equipments

Item Model Count


Robotic Spot Weld Gun Nimak / ARO 8



Lift shuttle - 1



Robot Details



Lay-Out

Specifications


Number of robots 5




respot)

Visuals


Major Equipments

Item Model Count





Lift shuttle - 1



Robot Details



Lay-Out

Specifications


Number of robots 17




respot)

Visuals


Major Equipments

Item Model Count

Kuka Robot See next page for details 17





Lift shuttle - 1


Robotic Gripper Unit - 1


Robot Details




Lay-Out

Specifications


Number of robots 18




respot)

Visuals


Major Equipments

Item Model Count

Kuka Robot See next page for details 18





Lift shuttle - 1


Robotic Gripper Unit - 1


Robot Details



1.9. Underbody

Lay-Out

Specifications


Number of robots 1


Conveyor type Semi-automatic lift shuttle in linked lines + chain conveyors

Process summary Spot welding of underbody frame and floor pan

Visuals

1.9. Underbody

Visuals

1.10. Manual Weld Guns

Item Count

ARO 191

PW 181

Nimak 7

Visuals


Specifications

Laser Cutting Booth (with 1 robot & source) OEM Robot: KUKA, LASER: Trumph, Cutting Head: Precitec Age: 2008 Booth Dimensions: 7,0 m x 5,0 m x 4,2 m

*One of the robots is not included into the sale package.

Visuals


Specifications

Automatic Stud Weld Station (2 robots with t-stud units & turn table) OEM Manipulators: ABB IRB 6400/2.4-150, ABB IRB 6400/2.8-120 T-Stud Units: Tucker Age: 2000

T-Stud Units Manipulator&Controller Automatic Stud Station

Visuals


Specifications

Pedestal Weld Machines (6 items) OEM Machine Type: Coşkunöz (Turkey) Age: 2000

2. ASSEMBLY SHOP

2.1. Skillet Conveyors

Visuals

Specifications

Number of items 52

Dimensions 6000 mm x 2800 mm x 450 mm

Notifications • Periodically controlled.

• Currently in use

2.2. EMS Carriers (for windscreen assembly)

Specifications

Number of items 2

OEM Daifuku (Japan)

Notifications • Electirified monorail system with vacuum generators

• Automatic elevation and manual windscreen assembly

Visuals

2.3. Body Overhead Conveyor Systems

Specifications

Number of items 29

OEM Daifuku (Japan)

Notifications • Vertical adjusting conveyor

• Maximum payload capacity: 1291 kg (work capacity)

Visuals

2.4. Engine Mounting Dollies

Visuals

Specifications

Number of items 6

OEM Daifuku (Japan)

Notifications • Payload capacity (incl. Tooling plate): 450 kg

• Superstructure: Hydraulic scissors lift with tooling fixture

2.5. Engine Assembly Dollies

Visuals

Specifications

Number of items 22

OEM Daifuku (Japan)

Notifications • Payload capacity (incl. Tooling plate): 350 kg

• Track length: 19,635 m

• Plate pitch: 800 mm – Work pitch: 2400 mm

2.6. Fluid Filling Stations

Visuals

Specifications

Number of items 4

OEM Dürr – Schenck (Germany)

Notifications • Windscreen washer water, coolant fluids, air conditioning gases

and brake fluid filling combined

2.7. End Of Line Lift and Conveyor

Visuals

Specifications

Number of items 1

OEM Daifuku (Japan)

Notifications • Vertical lift

• 2(600) x 91400 mm double slat type end of line chain conveyor.

• Pitch: 6000 mm

Contacts

Sale, Operation and Logistics Issues

Ayhan Kalkavan – Managing Director, Global Industry

[email protected]

Sedat Demir – Sales&Marketing Director, Global Industry

[email protected]

Kemal Karakaş – Operations&Logistics Director, Global Industry

[email protected]

Technical Issues and Package Content Details

For Body Shop Content,

Gökan Acar – Maintenance Engineer, Ford Otosan

[email protected]

For Assembly Shop Content,

Murat Doğan Ercan – Automation&Projects Engineer, Ford Otosan

[email protected]

mailto:[email protected]












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