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INSIGHT May 5, 2002 Europe - Robots have been performing welding tasks for long enough to be considered a mature application, and robot manufacturers and systems integrators have developed extensive experience and knowledge about robotic welding. The next logical step, after developing thousands of custom welding applications, was to take that experience and knowledge and develop pre-engineered arc-welding workcells. Most robot manufacturers that make welding robots, and some integrators and welding companies, make such standardized arc- welding workcells to handle an array of applications, from welding small to large workpieces at medium to high volume. The beauty of standard cells, or arc-- welding solutions, is that the engineering has already been done. A typical cell includes guarding, a robot (or two or three) and robot controller, a positioner, a power supply, a torch and safety equipment. Depending on the manufacturer and the end users requirements, options include tool-centerpoint calibration, through-arc tracking, torch cleaners, process monitoring, seam tracking/finding and vision. Besides the typical benefits of using a robotic system - including the ability to handle multiple parts or jobs, fewer safety and ergonomic problems, higher throughput, higher quality and fewer costs associated with hiring, training and paying employees - standard robotic arc-welding cells are less expensive than a custom- built system. They're easier to install and relocate, which saves money on installation and allows manufacturers to ramp up more quickly. Here is a roundup of standard arc-- welding workcells from robot companies. ABB's Welding Systems Division manufactures a line of standard FlexArc arc-welding cells. Cells range from the FlexArc U, for welding brackets, simple frames, brake parts and more; to the FlexArc K-205, for welding large workpieces, such as motorbike frames, fork truck, off-road vehicle components and heavy-equipment parts. Options include BullsEye TCP calibration, torch cleaning assembly, SmarTrac sensing system, through-arc tracking and tooling fixtures. Cloos last year introduced a line of pre-engineered robotic welding cells. UniverCell systems are available in a variety of configurations to meet the needs of specific welding applications. All equipment in the UniverCell, including safety fence, safety light beams, robot controller and welder, is mounted to a common steel base, allowing for fast installation and easy relocation. Numerous options ensure a system that will work for end users' specific applications. The company designs and builds all cell components and fixtures, and turn-key packages are available in conjunction with the UniverCell systems. Daihen offers several workcells, including the Dynamic Arc Cell FW 100 (Ferris Wheel) welding system for larger parts, the "T" Series (four models) of turntable welding systems for small workpieces and the Dynamic Arc Cell E100 for production runs of medium to high volume. Options include arc monitoring, dual robot systems, seam finding/tracking, offline programming and watercooled torches. Genesis, an integrator of welding and cutting systems, offers a range of robotic welding and cutting workcells under the Versa- System name, incorporating KUKA, Panasonic Factory Automation and FANUC Robotics robots. Among them are the VersaSystem 1, compact turntable workcell designed to handle high-volume, medium-size parts; the Versa-System 2G, a two-station cell designed for the job shop manufacturers with low to medium part volumes and high changeover applications; and the Versa-System 4M, a three-axis, Ferris wheel-style cell designed to handle large or multiple high- volume parts. Options include servo positioners, disc-emulation software, seam tracking, touch sensing and tool centerpoint checking. Lincoln Electric offers five welding workcells that handle small, medium and large parts. Configurations range from the System 10, a two-fixed-table design with a FANUC ArcMate 50iL robot; to the System 50, a dual-headstock design that features a FANUC ArcMate 100i robot for welding parts that need to be rotated to reach welds on multiple sides. Cells include robot controller, a choice of Lincoln power sources, safety equipment and ArcTool software. Options include water-cooled torches, automatic torch cleaning, through-arc seam tracking, TCP adjustment, auxiliary axis packages, multi-equipment software and more. Motoman makes a range of ArcWorld cells, which can be configured with a second (and sometimes third) robot, including ArcWorld II- 100HD for small to medium-sized parts that don't require repositioning; ArcWorld II-- 200 is the ideal solution for manufacturers with mediumto high-volume production runs of small workpieces; ArcWorld II-6200 and -6300 HD for complex applications that require welding in multiple planes; ArcWorld II-500 for parts that may require repositioning; ArcWorld 7000, with a five-axis positioner, for complex parts; ArcWorld III-1000 for high-volume applications; and ArcWorld 6000 for complex applications that require welding in multiple planes. Welding options include watercooled torches, torch maintenance package, seam tracking/ finding, process monitoring, calibration software, ToolSight torch control software and more. PANASONIC FACTORY AUTOMATION Panasonic offers seven PerformArc cells for various types of welding jobs and a choice of positioners, including fixed table, rotating table, rotating table with headstock (or head/tailstock or dual head/tailstock) or a Ferris wheel positioner with head/ tailstock. Modular components permit rapid tooling change by the user. Safety features are programmed within the PLC master control to prevent the potential of overriding safety checks. Six optional robots are available, with options that include dual-robot configuration, seam tracking, upload/download software and heavy payload positioners. KAWASAKI ROBOTICS Kawasaki manufactures several Portable Mini-Cells for MIG welding, including the Type 1 cell with dual work stations; the Type 2 cell, with dual index work stations; and the Type 3 cell, with dual index work stations and servo head/tail stock at each station. Options include a torch ream station, tooling I/O interface package, touch sensing and laser vision.
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Source: Robotics World - Copyright Douglas Publications, Inc. Apr 2002
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