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| Exporting the One-Pack SM Systems |
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EG began designing/building the main GW in February 1979 with the intent that it would become part of the new welding system they were planning to introduce to the mass-production line. The mechanism of the system was as follows: A carriage jig was used to position the floor assembly welded on the subline and feed it into the main GW. Then, the inner and outer side panels were introduced from the sides of the GW and placed in the welding jigs. The parts were then welded as the jigs turned inward, upon which they would be transferred to the carriage jig. Subsequently, the roof, upper dashboard and rear tray were assembled from above the GW and simultaneously spot-welded at approximately 150 points. This mechanism facilitated the completion of the white body in just one process. Jig changeover was completely automated (around five minutes), making it ideal for the production of multiple models. The system was known as the SMGW, with SM standing for the initials of subassembly and main assembly, since it integrated the subassembly and main assembly of side panels. The development of Honda's new robot station began in April of that year. Based on the station concept of integrating robots programmed for different operations, the team worked to design small, lightweight robots having the optimal dimensions and structures for their respective sections, including door and window openings along with general body surfaces. Four types of robots were conceived for different welding operations, and flexible installation positions were adopted according to the sections to be welded. For example, the floor-welding robots were placed at sides, while those used to weld window areas were suspended from above. This contributed to a reduced requirement for installation space. These robots were called "function" robots. The development team systematized these original Honda function robots and installed a total of fourteen units. Eight units were positioned at the first station in the additional welding process, while six were placed in the second station. The robots were called "monkey" and "crab" robots, according to their points of installation. The monkey robots, installed on the ceilings and walls around the robot station, were mainly used to weld areas around door openings and front/rear windshield mounts. The crab robots, placed on the floor, were used to weld body floors. Since the monkey robots and crab robots were placed three-dimensionally above and below, and to the right and left of the line, they gave rise to the allusion "monkey and crab war," which became a popular phrase at EG. Unlike the famous Japanese "Monkey and Crab War" folktale, which is basically a story of vengeance, the "monkey and crab war" here referred to a joint attack by a united army of monkey robots and crab robots, which performed additional welding of various body sections at once from all directions: above, below, right, left, front and rear. These robots eliminated the portable jungle from the welding line, further enhancing the integrity of body welding and assembly. The use of a teaching function also allowed each of the function robots to learn the different operations employed for different models. Switching between these settings was automatic, creating an effective system that was conducive to multiple-model production. Installed along the newly developed welding system were the subassembly machines, which were dramatically downsized through the use of process integration, and the robot stations, both of which were placed close to one another. The completed line was much smaller than conventional welding lines of the period. This system is generally called the one-pack SM system. |
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