In short

O-Flex, an automotive supplier producing protective thermal sleeves and safety components, needed to automate a new, technically challenging part that couldnot be produced using manual labor or traditional hard automation. The application required precise punching on both ends of a highly flexible,multi-layered material while maintaining tight tolerances and efficient throughput.

Working with system integrator BlueBay Automation, O-Flex implemented a collaborative robot solution built around a Kassow Robots 7-axis cobot.

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Challenge

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O-Flex supports automotive OEMs with highly specialized protective components, includingthermal sleeves used to shield electrical and hydraulic lines from abrasion andheat. A new customer program introduced a sleeve design that required precisepunching operations on both ends of a flexible, corrugated, multi-layeredmaterial.

Manual processing was not a viable option due to the repetitive nature of the task and thephysical demands placed on operators. Traditional hard automation solutionswere also explored but proved problematic. The quoted systems were expensive,occupied significant floor space and still could not achieve the required notch dimensions for the part.

Compounding the challenge was product life cycle uncertainty. O-Flex had previously invested in dedicated automation equipment that became unusable once a program ended. Forthis project, the company needed a solution that could meet productionrequirements without becoming a stranded asset in the future.

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Solution

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BlueBay Automation designed and delivered a fully integrated collaborative robotic cell using aKassow Robots 7-axis cobot as the core automation platform.

The system automates machine tending for the punching process by feeding the thermalsleeves, positioning parts into custom presses on both ends and verifyingquality through an integrated vision system before sorting parts intoappropriate output totes. Theseventh axis provided greater freedom of motion than atraditional 6-axis robot, allowing the cobot to approach the flexible,multi-layered material from optimal angles while maintaining precisepositioning. This flexibility also enabled the robot to be mounted to the sideof the machine rather than directly in front, improving access for operatorsand maintenance teams while keeping the overall cell footprint compact.

Instead of fully enclosing the system, only the hazardous punch zones were guarded. This approach preserved the collaborative nature of the application and allowed operators to observe the process, perform inspectionsand address minor issues without extensive downtime.

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Key design components included:

·      Compact footprint: The cobot cell fits into a tightproduction area where floor space is at a premium.

·      Accessibility: By mounting the robot to theside and guarding only the hazardous punch zones, operators and maintenancepersonnel can safely access the machine without full enclosure.

·      Ease of use: The intuitive programming environment enabledO-Flex teams gain confidence quickly.

·      Redeployability: Unlike dedicated hardautomation, the cobot is a reusable asset that can be retooled for futureapplications.

Cycle time requirements were validated during thedesign phase using simulations and test runs, ensuring the system could meetproduction demands without sacrificing the collaborative design benefits.

Benefits  

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Since commissioning, the Kassow Robots cobot system has operated reliably in dailyproduction for more than three years, completing over 1.2 million cycles.O-Flex has already achieved its estimated return on investment, which wasoriginally targeted over two years. These benefits included:

·      Production reliability: The system met tight launch timelines without missed customer shipments.

·      Operational efficiency: Automation eliminated repetitive manual tasks, allowing operators to focus on higher-value activities.

·      Long-term confidence: The cobot has demonstrated durability and consistency over extended runtime in a demanding automotive environment.

Equally important to O-Flex was the collaborative relationship with BlueBay Automation. Open communication, transparent problem-solving and responsive support helped address early tooling challenges and ensured the system continued to perform as intended.

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For BlueBay Automation, selecting Kassow Robots was a deliberate decision. The7-axis design enabled greater freedom in robot placement, improved reach within a compact cell and avoided common singularity issues seen in some 6-axiscobots. The platform’s user-friendly programming environment reduced the learning curve for O-Flex’s team, while the robust construction provided confidence for long-term operation.

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The result is a collaborative automation solution that balances performance, accessibility and adaptability, delivering value well beyond theinitial application.