Tailored Robotics Integration for Automotive Applications

Automating processes using robots presents many challenges for companies. That’s why they turn to experienced experts like Human – Robot Solutions S.L. in Spain. Based in Almassora near Valencia, this company is a system integrator for automation solutions, particularly for production lines in the automotive sector. Their projects combine various customer requirements with deep expertise in robotic automation to deliver robust and long-lasting solutions.

In one such project, a production line for plastic car body parts needed to be automated. The process required several work steps, carried out by different types of robots. A Pick & Place robot positioned plastic parts for cutting, involving rapid rotary movements of the robot arm. After cutting, plastic particles needed to be vacuumed off to prevent scratches during the subsequent polishing step. Separate robots handled both the suction and the transfer of cleaned parts to the polishing machine.

System Integrators Help Select the Right Components

An important role of Robottions in this project was to select the most suitable components for each process step. Industrial robots typically come with standard equipment that often doesn’t meet the end customer’s specific needs. Energy and media supply lines to the robot arms, for example, are usually implemented using basic corrugated tubing without retraction systems.

Simulations or factory tests often reveal that standard tubing is not durable enough for real-world production. In high-speed movements, the tubing kinks, loops, and wears down quickly, often needing replacement shortly after installation. This leads to increased costs, especially if failures become frequent.

Media supply for the vacuum robot presented additional challenges. Vacuum hoses were traditionally routed via ceiling-mounted structures such as overhead gallows or spring-loaded balancers. These setups are complex to install and maintain, frequently halting production. Cable length also posed issues—excess slack could create loops during robot movement, leading to snagging on parts or structures. All of this reduces production line profitability and customer satisfaction.

The Right Dresspack for Specific Customer Needs

To address these issues, Robottions regularly relies on Sumcab’s innovative and durable energy and media supply solutions.

For the plastic body parts production line, Robottions and Sumcab jointly analyzed the requirements for each robot’s media supply:

• The Pick & Place robot was equipped with the Sumoflex retraction system. Instead of a loose corrugated hose, the system uses a guided tube with a built-in spring return. This adjustable solution ensures the correct hose length is always available and that it remains tightly guided along the robot, avoiding kinks or abrasion even during complex motions.

• For vacuum hose routing to the robot’s wrist axis, the Sumoslide twin system was installed. Both hoses are mounted on a carriage that runs directly along the robot. A spring mechanism ensures the hoses move in sync with the robot, reducing wear. A key benefit is that ceiling-mounted gallows are no longer needed—Sumoslide compensates for hose length changes directly, allowing for a more compact and accessible setup. This makes a positive difference in both initial installation and in future maintenance or repair operations, as ceiling setups are usually very time-consuming to remove and reinstall.

Optimized Energy and Media Supply Increases System Productivity

Thanks to its collaboration with Sumcab, Robottions can offer clients superior energy and media routing solutions for industrial robots. In this project, standard corrugated tube systems were replaced by durable, reliable alternatives. Sumcab’s solutions also reduce the number and duration of service calls, lowering costs for end users and boosting production line efficiency—key benefits Robottions is proud to deliver.

At a glance

Reliable energy and media supply for robots thanks to SUMCAB

Situation
Robottions is a system integrator for robot-based automation solutions. In an automotive project to automate a production line for plastic car body parts, various robots were used, each with different demands on their energy and media supply systems.

Challenge
The robots’ specific applications required dresspacks that could handle fast movements and multiple media lines. However, most robot manufacturers supply standard corrugated tubes that are not built for high loads, resulting in wear and frequent replacements.

Solution
Robottions used Sumoflex and Sumoslide systems from Sumcab to optimize robot energy and media routing. These customizable retraction systems allow close, efficient guidance along the robot arm that adapts well to its movement.

Result
With the optimized energy and media systems, Robottions delivered a high-quality automation solution to its automotive customer. Thanks to Sumcab, the solution is now significantly more durable and easier to maintain, leading to reduced costs and increased efficiency across the production line.