INTEGRATOR OF NEW AND USED ROBOTS FOR INDUSTRIAL AUTOMATION

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• More Output
• Labor Cost Savings

• Repeatability
• Speed
• Improved Return On Investment (ROI)

Project Summary:

A metalforming company needed a robotic welding system that would create consistent, cosmetic welds on thin exhaust heat shields for motorcycles.

Faced with the company's stringent weld requirements, RobotWorx chose to use Fronius Cold Metal Transfer (CMT) technology. This innovative welding process provided the low heat signature necessary to affix mounting clips without distorting the shields.

Application Goals

• Welding Method: As mentioned above, eliminating part distortion and spatter was very important to this customer. Because the motorcycle parts being welded were so delicate, the customer was not sure which welding approach would provide the best results: cold metal transfer, mig, tig?
  
  After seeing and testing a variety of methods on the parts, RobotWorx' engineering team was able to achieve the best, spatter-free welds using Fromius CMT technology.
  
  
• A Complete System: The customer was looking for a complete turnkey system with a turntable to present parts and a reliable welding robot. A full safety environment was also required. The RW1050 workcell fit the bill.
  
  
• Speed: Cycle time and efficiency were key. Not only did the robot need to be able to weld quickly, the welding system needed to feature a parts positioning table that indexed quickly. The RW1050 has a dual-sided turntable which allowed for faster cycle times and greater productivity.
  
  
• Affordability: Keeping the overall cost of a complete system like this can be a challenge. RobotWorx met the customer's need for a lowered price tag by outfitting the system with a fully reconditioned robot arm. 
  

RobotWorx Solution

• RobotWorx RW1050 Workcell: The RW1050 is one of RobotWorx' best selling workcells with a 180 degree indexer with dual stations, a common base for easy moving, a single robot, plus the tooling, safety and welding package.
  
  
• Welding Robot: Reconditioned Motoman UP6 XRC 6-axis, medium-reach robot with a 6kg payload capacity.
  
  
• Fronius CMT Power Source: RobotWorx outfitted the workcell with a Fronius TransPulse Synergic 3200 CMT MV Mig inverter power source to achieve the cosmetic welds. CMT does not input very much heat and works very quickly.
  
  
• Welding Torch Assembly: A water-cooled welding torch and drive assembly also helped to keep heat input to a minimum. RobotWorx outfitted the Motoman robot with a Fronius Robacta Drive CMT hose pack.
  
  This specialized drive along with a torch mounted wire feeder allowed for quick, welding wire retraction -- the key to low-heat CMT welding. A Fronius Robacta MTG 4000 torch was used and a Binzel Robot Mount CAT2 provided quick, precision movement. 
  
  
• Safety Environment: The RobotWorx RW1050 is enclosed with rigid steel safety walls. The two steel mesh doors on either side of the cell are equipped with electronic door interlocks and arc glare protection. A set of light curtains and an arc-glare divider in the middle of the table keep the operator and person loading the workcell safe.
  
  
• Controls: Motoman XRC controller and teach pendant came with the system as well as an operator station for inputting quick commands and emergency halts.
  
  
• Support: RobotWorx provided free robot programming training and a warranty covering 100% parts and labor for a year after shipping. 
  

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