(Applied in one of the motorcycle manufacturing company in Algeria)
Customer Requirement
1.Use robot to replace labor force for welding. Manual loading and
unloading of product. One time fixing of the product onto the
fixture. 2.Workpiece material: steel tube, wall thickness: 2-6mm;
Size: 300 x1500mm 3.The workpiece should be welded alternately on
both sides and request to reduce the deformation. The flatness of
the workpiece should be +/-1mm. 4.First welding of the small parts,
then assemble the frame and do welding welding. Accept the finish
welding of the whole products into several steps.
Solutions
1.The complete welding robot system includes 3 sets of HS-R6-08
1.4m arm length robot, 3 sets of 350A MIG welding machine, 3 sest
of automatic anti-collision welding gun, 2 sets of double axis
positioner, 2 sets of one-axis vertical rotation positioner and 2
sets of fixed table, 3 sets of welding gun cleaner, and 6 sets of
welding fixtures, etc. 2.In order to guarantee the stability and
consistency of welding quality, we suggest to equip with welding
gun cleaner device. 3. Automatic welding is carried out by a
six-axis robot MIG welder. The cylinders or fast clamps are used to
fix the position of the product with the lever principle to ensure
the positioning requirements of automatic welding of the robot, so
as to ensure that it can be welded to each part of the product.
According to the requirements of production efficiency, two sets of
positioners are designed, one for loading and unloading of the
workpiece, and the other for welding.
Workflow
1) Manual loading of the workpiece to the fixture in Station 1
positioner; 2) Start welding; 3) The robot and welding machine will
do welding on the workpiece according to the presetting program; 4)
Welding completed; 5) While the station 1 is being welded, station
2 is being loaded and fixed the work piece synchronously. Two
stations work alternately. 6) Cycle working 7) This machine can
achieve automatic welding with manually loading material. It can
also improve the welding quality and welding efficiency. What’s
more, it can reduce the production cost. The problem of unstable
quality and low production efficiency caused by pure manual
operation has been solved. Application Effect 1.Double-station
positioner layout can realize long time continuous welding, welding
efficiency and welding quality has been significantly improved;
2.The positioner realizes the workpiece clamping at one time, and
automatically realizes the alternating welding of the front and the
back side of product, so that the deformation is effectively
controlled. 3.This machine can achieve automatic welding with
manually loading material. It can also improve the welding quality
and welding efficiency. What’s more, it can reduce the production
cost. The problem of unstable quality and low production efficiency
caused by pure manual operation has been solved. 4.Robot replace
manual welding. Welding industry is a high-risk industry, high
temperature, arc light and welding smoke have a certain impact on
the physical and mental health of workers; 5.It is an inevitable
trend to use robots to replace welding robots in welding, which is
not only the promotion of the market, but also the requirement of
technological upgrading.
