AUTOMATION AND ROBOTICS
to an industrial robot on accuracy , precise repeatability and stability . This means that small and very small series batches can be produced without extensive programming efforts , and the operator is protected .
Welding process analysis
If components are not precise or equipment is unstable , additional measurement traversals are often required to ensure exact positioning . This quickly makes the entire process inefficient .
If done manually , however , the welder can immediately respond to changes and notice if the sheet metal is moving during welding , for example . In this case , the robot would simply weld a few millimetres next to the desired position . This means that the weld seam is in the wrong location and the component cannot be used . That is why the welding process should be analysed down to the smallest detail beforehand .
Does it even make sense to switch over to automated production ? Do so many changes have to be made that the idea is no longer economically worthwhile ? Suppliers must support potential users with competent advice during the planning , installation and commissioning of welding cells . This includes a comprehensive initial consultation , concept creation and a feasibility analysis . The component to be welded must be thoroughly examined and evaluated .
Before operation-ready set-up on-site , initial sample welding should also be carried out on the supplier ’ s robot welding systems . The customer receives a comprehensive introduction to programming and can check the welding process and results . Once the system has been selected , the customer receives comprehensive training in operation and professional support is also provided after the system has been installed .
“ The most crucial factor isn ’ t the robot , but rather the welding technology in use . To achieve the best possible results , suppliers need to provide the necessary professional competence ,” said Wolfgang Kumpf , Head of In-House Sales , EWM .
Automation in chassis production
EWM-EUEN GmbH implemented an automation solution with a welding robot for a lorry trailer manufacturer . The skid trailers and roll-out trailers are always manufactured from the same assemblies . New clamping equipment was intended to make work on the 7m-long and 2.4m-wide trailers easier for the welders .
EWM-EUEN GmbH implemented a gantry system with nine axes . A Phoenix puls welding machine from EWM was used . The skid trailers and roll-out trailers are each produced in two separate working areas .
Whilst the robot is welding in one section , the other can be loaded . Welders insert the longitudinal girders and welded assemblies , tack weld them and then weld extra-short seams straight away . When the robot has finished welding in one booth , it moves into the second booth and continues welding there . The finished chassis is then removed , and the cell is loaded again .
While the timing of the robot was initially a major challenge for welders , the workflows are now running smoothly . As the entire welding process is based on taught-in curves , there cannot be any major deviations among the individual components ; this presents a major challenge during part preparation . The thermal expansion of components also had to
About EWM
For over 65 years , EWM has developed innovative arc welding technology made in Germany . The family company has come a long way since it was founded in Mündersbach , in Germany ’ s Westerwald region , in 1957 . It now has over 400 sales and service support outlets across the globe , and is one of the world ’ s leading producers of welding technology . The EWM product range contains sustainable all-in-one solutions and technology “ for every kind of welder ”.
In addition to smart machines , EWM develops and produces all necessary components , such as welding torches for manual and automated applications . Many EWM welding processes are patented and are designed to save energy , materials and time as well as reduce welding fume emissions by up to 75 % and make welding more sustainable . EWM also offers comprehensive service and consultancy .
Left : Even very large components can be produced using automation . This robot welding system was equipped with an alpha Q from EWM , new EWM welding torches and ewm Xnet 2.0 .
be considered . It therefore took a few passes for the welders to program the components to ensure optimal contact with the weld seam at all times .
Productivity increased enormously because of chassis production automation . The manufacturer was able to nearly double its production with reduced manpower . Threehundred weld seams can now be created within 90 minutes . Because of the quality of the weld seams and minimal weld spatter , subsequent reworking was reduced by 30 per cent .
In conclusion
When automating welding processes , it is essential to view the system holistically . The focus should be on welding , not the movement of the robot . This cannot replace trained professionals , but it can relieve the burden on them when it comes to carrying out monotonous and exhausting work . This frees them for activities which create more value .
In short , a successful transition to automated welding processes during skilledworker shortages can be a sensible solution which measurably increases productivity and competitiveness . n
In this application from EWM-EUEN GmbH , the robot reaches operating points at both the top and bottom of the positioned chassis frame over a long Z-axis . In the high position , the Z-axis is located up high between the two extraction sections . www . ewm-group . com / en /
ISMR September 2023 | ismr . net | 45