Building a super sports car doesn’t just require the delicate touch of a human hand – high-tech robots and artificial intelligence are needed to streamline the manufacturing process.
At Lamborghini’s Urus factory in Sant’Agata Bolognese, its high-performance SUV is built using digitization, automated vehicles and robots as well as trained technicians who work at ergonomic stations.
Here’s a snapshot of 10 high-tech tools used to build the Urus. About 40 SUVs roll off the line every day at the plant in Italy.
Painting takes place inside Lamborghini’s paint shop before the body shell enters the assembly line in the main plant. The shells and all body components are painted using robots. Robots are faster, more accurate and more efficient than humans. But technicians do the final inspection of the bodywork. Under bright lights, they walk around the vehicle to make sure the body is painted perfectly and there are no air bubbles or streaks. In the paint facility, 22 per cent of the water used is recycled and 95 per cent of vehicle paint colours are water based, which reduces emissions of volatile organic compounds (VOCs) and improves air quality.
The shells and all body components are painted using robots.FEDERICO VECCHIO/Courtesy of manufacturer
Under bright lights, technicians make sure there are no air bubbles.Courtesy of manufacturer
The Urus body is engraved with a vehicle identification number. Each VIN code has a unique build manifest so technicians know what each customer wants on their vehicle. Once it has a VIN, the body shell travels to the pre-assembly line on an automated guided vehicle. The AGV travels autonomously on electromagnetic rails, moving the SUV from one station to the next in 30-minute intervals. The AGVs move with pinpoint precision owing to GPS, laser and LIDAR [light detection and ranging] sensors that visually map the shop floor and its surroundings.
The vehicle body travels to the pre-assembly line on an automated guided vehicle, which uses GPS and Lidar.Courtesy of manufacturer
In the pre-assembly area, technicians have many tasks such as assembling the thermal and acoustic insulation, soundproofing the cockpit, attaching the seat belts and wiring and marking the VIN code on the dashboard. At some stations, robots lift and rotate the body so technicians can work in the most ergonomic position. Humans never lift any heavy weight and they never work lying on the ground. They always work next to the body. In some cases, robots turn the SUV 90 degrees so technicians can access the car better.
Robots turn the SUV 90 degrees so technicians have better access to the vehicle.Courtesy of manufacturer
Further down the line, technicians assemble the front and rear windshields as well as all side windows using collaborative or “sealing” robots. An automated robotic arm applies the glass adhesive and sealant, which is made of polyurethane, to all edges of the windshield. A pressure sensor ensures precise application and a high-quality finish. The process takes only a few minutes.
An automated robotic arm applies the glass adhesive and sealant.FEDERICO VECCHIO/Courtesy of manufacturer
Once applied, the robot moves the windshield into position at the front of the body. Afterwards, two technicians fix the glass to the body manually to ensure it is securely in place. The same process is repeated on all glass windows.
Technicians fix the glass to the body manually.Courtesy of manufacturer
Ergonomic machines help technicians install the instrument panel, or IP, easily. The IP is heavy and awkward, but sliding it into the body takes seconds with the help of these machines. Small automated robots also move smaller components, such as electric modules or fasteners, around the floor so workers don’t have to go back-and-forth to get them. Automated transport trolleys pick up parts from people in the “supermarket” area and move them to different assembly stations.
Ergonomic machines help technicians install the instrument panel.Courtesy of manufacturer
Technicians don’t carry documents or paperwork around – instead they take advantage of digitalization on the shop floor. They use high-tech touchscreens located near each station to easily access information about a specific vehicle using the VIN number so they know exactly what options to add to each vehicle. This helps optimize times while reducing waste and providing a greener alternative to using paper. AI helps improve efficiency by analyzing data and predicting maintenance problems, potential failures and bottlenecks on the line and optimizes the build sequence of vehicles.
Technicians use touchscreens located near each station to access information about a specific vehicle.FEDERICO VECCHIO/Courtesy of manufacturer
The marriage station uses sophisticated robotic equipment to attach or “marry” the engine and chassis together. It’s a mesmerizing act and the most complicated area on the shop floor. Robots do all the heavy lifting – moving the powertrain, including the engine, transmission, calipers and exhaust system and automatically attach it to the chassis.
Robots do all the heavy lifting at the marriage station.FEDERICO VECCHIO/Courtesy of manufacturer
A tire robot is used to carry wheels from a storage area to each corner of the SUV so workers aren’t burdened with the task of transporting heavy tires. The robot lifts and aligns the wheel to the bolt holes and then technicians step in to finish the job, tightening the bolts with a high-impact wrench.
A tire robot carries wheels from a storage area to each corner of the SUV.FEDERICO VECCHIO/Courtesy of manufacturer
Near the end of the line, technicians perform quality control tests on every part of the SUV. Then, the engine is turned on and the vehicle is driven to the dynamic vehicle testing area. Road tests are conducted afterward to test the suspension and ride-and-handling before the SUV is delivered to the customer.
Technicians perform quality control tests on every part of the SUV.Courtesy of manufacturer
The writer was a guest of the automaker. Content was not subject to approval.