In the highly competitive heavy fabrication industry, a company’s competitive edge needs to be developed all the time. Complete robotic welding solutions provide the focus and optimization the company needs, in order to be more dynamic and deliver more value to the customer.
In order to raise the level of automation and improve overall productivity, welding manufacturing operations must be considered as a chain of process steps and should be arranged according to lean manufacturing principles.
When implementing factory automation, robot production cells are the basic building blocks for modern factories. The work steps that are time-consuming and no longer bring value to the production chain, are eliminated from the work chain as robots are put in work.
Benefits of complete robotic welding solutions:
- Reliable pre-analysis: Virtual robotic solution design through 3D-modeling and simulation
- Typically achieved automation rate in welding from 50 to 80%
- Deposit rates up to 9 kg per automatic program running hour with only one MIG/MAG torch
- Systems can be utilized 24/7 and 8760 hours per year
- All components and services from one supplier
Complete robotic welding solution: Anatomy
During the past decade, robotic welding has been one of the most increased industrial applications. Because of the flexibility and level of productivity that those solutions bring; robotic solutions can be designed for one-off or mass production, large reaching dimensions, and offline programming systems.
Typically, the complete robotic welding solution consists of a workpiece handling solution and gantry (half portal) with one to three linear axis.
The robotic cell comes with suitable programming and cell control software systems that are chosen according to the machinery and production needs. Additionally, welding process evaluation, proper safety equipment for the robotic cell, and machine life-cycle management services come as standard.
Each unit of the complete solution, such as handling equipment, welding process or the software system used, is analyzed and selected according to production requirements and customer needs.
Pemamek’s typical complete robotic solution consists of work piece handling solution, gantry (half portal) with one to three linear axis, PEMA WeldControl 300, CellControl, safety equipment, as well as welding process evaluation and machine life-cycle management services.
Versatility through modular handling solutions
Effective and accurate workpiece handling is one of the most important parts of successful robot welding. When robotic welding cells are based on modular robot tracks and positioners, the design of the production cells can be optimized by selecting the most suitable handling module.
A 3D-modelling of the production cell and welding reachability analysis verify the selected layout and draw the footprint of the cell.
Complete robotic welding solutions ensure maximum efficiency even in high-mix low-volume production.
Successful implementation of robotic welding solution
The saying “Well planned is half done” applies also to robotic welding solution investment. When the real need and demand are defined, the solution can be better designed to meet the customer’s requirements. Also, fast ROI will be achieved.
These 5 steps will lead to the successful implementation of a robotic welding solution:
- Thorough pre-design together with the supplier and purchaser.
- Possible design changes in the products for example changing groove geometry or groove preparation method.
- Welding process evaluation and modification into robotic welding.
- Tailored and thorough training for all the participants.
- Good level of maintenance and follow up together with the supplier.