Robotic Cells
Overview
Highly-regarded competence in robotic programming for different applications:
Persico offers the perfect solution for high-quality covered interior parts. Our fully automated robotic cells combine flaming/plasma treatment, prefixing, gluing, covering and edge folding operations in a single process.
Different covering materials, even with decorative stitch lines, are prefixed while the cell is performing the flaming / plasma treatment before gluing. In the second step, the covering and edge-forming processes are carried out.
Advantages
- Cost saving
- Potential energy saving
- Different processes integrated into a single cell
- Factory footprint minimization
- Quick process
- Repeatability
- Mass production
- Potential waste reduction
Applications
Interior vehicle parts
- Instrument panels and centre consoles
- Door panels and seat backs
- Headliners, pillars and sun visors
InStitch™ technology
What’s InStitch®
The 3D stitching process implements a sewing head on a robotic arm that precisely sews 3D-formed leather along the path indicated by a CAD model.
Why InStitch®
The high-quality standard achieved by this process drastically reduces the scrap ratio of manual sewing. InStitch® is particularly effective with large, complex parts like instrument panels.
Persico InStitch® technology advantages
Optimized cost
Process cycle time reduced by 30% compared to our competitors, thanks to the Real Time Scanner.
Updated features
- Swivel tool changer eliminates external cables running from axis 3 to the sewing head
- Robust sewing head design and construction
- Simplified head changing system with carriage
Best Quality
Real time scanning (RTS):
- Accommodates greater part variation (+/- 5 mm from nominal)
- Provides alignment accuracy of +/- 0.5 mm
- Reduces part rejects
Design freedom
- Improved clearance under part fixture for sewing head accessibility
- Predictive tools
- Simulation software program uploadable to robot; minimal part tuning required
- RFID utilized to confirm proper matching of sewing head and part fixture to the program
Persico’s robotic scoring cell weakens the skin or fake skin in the airbag areas of instrument and door panels. The breakthrough areas for controlled airbag deployment are scored by blades and a tracking system, ensuring precision high-quality results.
Advantages
- Processing of a variety of materials: leather and fake leather
- High precision measuring system for leather thickness
- Traceability system
- Compact footprint
- Very easy relocation
Applications
- Instrument panels
- Door panels
Optional features
- Incorporation of release agents
- Double-sided operation
Laser technology for a clean and precise cutting process.
The laser source is fixed and the robot moves the parts following the programmed path.
Quick connection allows for cutting different parts in the same cell. The technology can be used for cutting substrates or decorative materials.
Advantages
- Processing of different materials: substrate or covering stock.
- High repeatability
- Compact footprint
- Very easy to relocate
Applications:
- Door carriers, top rolls, inserts, map pockets, armrests
- Centre consoles
- Instrument panels
- Seat back panels
- Pillars
- Side trim
Optional features
- Turning table
- Dual loading/unloading station
The Persico hot melt spraying system is suitable for different glue applications, such as spraying and web spraying. The head can be fixed or assembled on the end of the robot arm. The glue application process can be realized as a stand-alone robotic solution or integrated into a Persico ALL-IN-ONE ROBOTIC CELL.
Advantages
- Hot melt or water-based glue process
- Processing of different materials: substrate or covering stock
- High spray homogeneity
- Compact footprint
- Very easy to relocate
Applications
- Door carriers, top rolls, inserts, map pockets, armrests
- Centre consoles
- Instrument panels
- Seat back panels
- Headliners
- Pillars
- Carpets
- Boots
Optional features
- Automatic cleaning system
- Turning table
- Dual loading/unloading station
- Integration with other processes
- Humidity control system
Persico’s robotic stapling cell is a good alternative to a with glue or glueless edge folding solution.
Advantages
- Cost saving
- Sustainability
- Compact footprint
- Very easy to relocate
- Quick process
- Repeatability
- Mass production
Applications
- Centre consoles
- Armrests
Optional features
- Multiple part production
- Automatic part unloading
- Inline prefixing
Persico’s robotic assembly cell for automatic clip assembling. Automatic check of shooting position, automatic clip shooting and automatic clip presence control (all in one).
Advantages
- Repeatability of clipping operation
- 100% control of clip presence during the cycle time
- High precision measuring system for leather thickness
- Traceability system
- Compact footprint
- Very easy to relocate
Applications
- Instrument panels
- Door panels
- Centre consoles
Optional features
- Turning table
Patented solution for 3D cutting consisting of a 6-axis anthropomorphic robot with a pneumatic head, equipped with a wear-resistant steel oscillating blade. SkillCut is a valid alternative to waterjet cutting cells.
Advantages
- Low-cost management and maintenance
- Lower noise level
- High flexibility
- Recommended for JIT production
- Clean system
- User-friendly software
- Offline programming
- High repeatability
- High-quality cut profile
Fields of application
- Automotive trim and interior parts (instrument panels, door panels/armrests, door top rails)
- Heat and sound insulation for cars and industrial vehicles
- Special applications
Optional features
- Fully automatic change of cutting program without impacting the cycle time
- Multi-cutting head
Spray skin
Drastic reduction in dead time.
Persico Automotive has developed EcoCover, a new spray skin process that achieves amazing results in a wide range of colours. It can even create faux stitching!
During the EcoCover process, a release agent is first applied to the mould.
Then, using in-mould coating, the paint is sprayed on, followed by a polyurethane (PU) material. The technique creates lightweight leather-like skins and allows for design freedom and extremely small positive radii. Thanks to the PU, the pieces have a pleasant feel and do not become brittle at low temperatures. Additional benefits of the process are very long tool life, material savings and lower energy usage.
Then, using in-mould coating, the paint is sprayed on, followed by a polyurethane (PU) material. The technique creates lightweight leather-like skins and allows for design freedom and extremely small positive radii. Thanks to the PU, the pieces have a pleasant feel and do not become brittle at low temperatures. Additional benefits of the process are very long tool life, material savings and lower energy usage.
Persico offers full production systems for dashboard instrument panels. In addition to the EcoCover process, we can provide skin cutting SYSTEMS, back-foaming TOOLS (in partnership with WIS Tooling) and TOOL CARRIERS, and punching tools and machines.
Persico Automotive has collaborated with Hennecke GmbH on testing the innovative EcoCover process.
EcoCover Pilot Plant / Prototype Area
Key Features
- 20 full instrument panels per day
- Climate-controlled booths with full control of temperature and relative humidity
- Manual trolley movement that can be easily automated
- Manual tool cleaning area
- Material storage and preparation area
Key Benefits
- PU material → NO PVC → NO brittleness at low temperatures + NO plasticizer migration due to ageing and NO visible airbag cut line after 6-7 years
- Design freedom
- Extremely small radii
- More pleasant feel
- Lightweight → over 20% less weight
- Lower material cost (very thin aliphatic PU layer)
- Little run-off
- Very long tool life
- Machine-block tools possible
- Very long tool life
- Machine-block tools possible
- Easy multi-colour masking
- Low energy consumption
Steps
Release Agent Application
Manual application in pilot plant
Automatic robotic electrostatic application on production line
Automatic robotic electrostatic application on production line
In-mould coating (IMC) with Aliphatic PU
UV-stable / long-term durability
Accurate hardness and haptics settings
Wide range of matt and glossy colours
Accurate hardness and haptics settings
Wide range of matt and glossy colours
Flash-off
Aromatic PU spraying
Less density
Lower cost
Perfect back-foam interface
Lower cost
Perfect back-foam interface
Hennecke PU-Spray System
Start and stop technology → NO over-spray
Air-supported high-pressure spray technology
Homogeneous thickness
Air-supported high-pressure spray technology
Homogeneous thickness
Curing
Manual Demoulding
