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To describe how Jaguar Cars in the UK is making use of a robot‐based intelligent adaptive metal inert gas (MIG) welding process incorporating laser diode measurement of the gap in the joint between the aluminium C‐pillars and the aluminium roof structure of its new XK sports car that is being built in the company's plant in Castle Bromwich, UK.

Describes the sensor technology that is used to guide the robot in order to undertake the MIG welding path.

The use of MIG welding in this particular application is essential if a perfect surface is to be achieved in a critical area of the car body before the aluminium body shell enters the paint shop. The introduction of MIG welding in this particularly exposed region of the car's body shell has proved to be a challenging experience for a wide range of engineers at jaguar cars in the UK, from manufacturing engineers through to process engineers and metallurgists, and others. The MIG welding of cosmetic aluminium skin panels is the result of considerable research work on the part of Jaguar engineers and the company's suppliers, as well as staff at Warwick University. This work is likely to continue in order to achieve a complete understanding of the entire production process, as well as to reduce cycle times and improve overall product performance, both to the benefit of the manufacturer and the end‐user – the customer.

It is likely that arising out of development work into new MIG welding techniques and processes, new standards will be used throughout the Ford organization, including other companies that form the Premier Automotive Group. Aston Martin, Land Rover Volvo could all benefit from the technologies developed at Jaguar Cars.

This is the first time that Jaguar Cars has used an ABB 2400‐16 robot in conjunction with a laser diode sensor to measure the true position of a seam prior to welding, allowing the robot's path to be optimised for each individual vehicle. This paper provides a unique insight into the development of a root‐based intelligent adaptive MIG welding process to produce a perfectly finished body shell.

Reviews the Essen Schweissen und Schneiden cutting and welding trade show, identifies mounting trend for electric servo guns to replace pneumatic welding guns, reports on growing interest in aluminium welding and outlines the different solutions proposed, assesses the latest developments in remote laser welding technology.

The paper aims to report on a new welding technology, TIP TIG.

The principle of operation and benefits of the technology are described together with a typical application.

The study finds that the technology provides the quality of TIG welding at the speeds of MIG welding, providing significant cost savings to the user.

TIP TIG provides a good opportunity for all users of robotic MIG welding to improve the quality of their product and reduce their costs.

The paper introduces a new and useful technology to the robot industry.

Discusses the application of low cost laser based seam tracking systems to welding robots in the automotive industry.

The automotive industry has been the principal driver in the development of robotics; however, as car design becomes more sophisticated, demands on robot makers will continue undiminished.

In common with many engaged in engineering manufacture, the welding fabricator is under continuing pressure to increase productivity in order to remain competitive in home and international markets.

The purpose of this study is to optimize and improve conventional welding using EMF assisted technology. Current industrial production has put forward higher requirements for welding technology, so the optimization and improvement of traditional welding methods become urgent needs.

External magnetic field assisted welding is an emerging technology in recent years, acting in a non-contact manner on the welding. The action of electromagnetic forces on the arc plasma leads to significant changes in the arc behavior, which affects the droplet transfer and molten pool formation and ultimately improve the weld seam formation and joint quality.

In this paper, different types of external magnetic fields are analyzed and summarized, which mainly include external transverse magnetic field, external longitudinal magnetic field and external cusp magnetic field. The research progress of welding behavior under the effect of external magnetic field is described, including the effect of external magnetic field on arc morphology, droplet transfer and weld seam formation law.

However, due to the extremely complex physical processes under the action of the external magnetic field, the mechanism of physical fields such as heat, force and electromagnetism in the welding has not been thoroughly analyzed, in-depth theoretical and numerical studies become urgent.

The current state in the application of lasers for cutting and welding is reviewed. Most cutting operations are performed on specifically developed laser machine tools such as the Trumpf Lasercell and its application in the development of trim shapes and low volume panel production at a sub‐contract toolmaker is described. Robots are mainly used with lasers for welding, particularly of vehicle body components where laser welds are found to be advantageous in reducing material weight and improving body strength. One example is the production of differing thickness panels and a robotic installation for producing car door inners is described. The benefits of the new generation of Nd:YAG power lasers are listed, including the ability to transmit the laser beam via fibre optic cables. This is particularly advantageous when robots are used to manipulate the “torch” and a new robot cell from Trumpf is described. Finally, the role of gases in laser processing is discussed.

Describes how Jaguar Cars in the UK is using robots to manufacture aluminium car bodies for its new XK sports car that is being built in the company's plant in Castle Bromwich, UK.

Describes the major production line techniques that are used in the manufacture of the body‐in‐white structure. These include self‐piercing rivets (SPRs), self‐tapping screws, MIG welding and adhesives.

The use of SPRs and self‐tapping screws are proving essential in the joining of aluminium components manufactured as extrusions, castings and pressings.

The introduction of SPRs and self‐tapping screws, adhesive bonding and MIG welding of cosmetic aluminium skin panels is the result of considerable research work on the part of Jaguar engineers and the company's suppliers, as well as Warwick University. Three of these techniques require the services of robots with their integrated controls. This work is likely to continue in order to reduce cycle times and improve overall product performance, both to the benefit of manufacturer and end‐user – the customer. This paper provides a unique insight into the development of a facility with islands of automation to produce aluminium body shells.

It is likely that arising out of development work into new techniques, processes and standards that will be used throughout the Ford organization, including other companies that form the Premier Automotive Group. Aston Martin, Land Rover and Volvo could all benefit from the technologies developed at Jaguar Cars.

This is the first time Jaguar Cars has used ABB robots in significant numbers to apply SPRs and self‐tapping screws to join aluminium components. ABB robots are also used for body shell inspection and MIG welding aluminum skin panels.