A store fixture fabricator needed to replace a manual welding application with a robotic solution to increase cycle times and weld quality. RobotWorx built a flexible and low-cost robot system featuring a Motoman EA1900N that provided the speed and consistency required to weld the steel fixtures together while remaining low-cost.
**Welding system video**
Application Goals:
- Feasibility: The store display units are made out of low carbon steel parts. The sheet metal (the thickest being 1/4"), wire forms, and tubes must be welded neatly and cosmetically to form various fixtures.
- System Versatility: The store fixture fabricator needed a robotic solution that could accommodate different sizes and types of units. The positioners, robot, and other components must be built in such a way that changes to the system could be easily made.
- A Specific Robot: In order to access welds on larger parts, the final welding robot solution had to provide a reach of at least 60 inches. The final fixtures can be as large as 4' wide by 6' long.
- Affordability: The final solution must remain within a specified budget.
RobotWorx kept system costs low by integrating a reconditioned robot. Reconditioned robots typically cost 40-60% less than brand new robot models.
RobotWorx Solution Details:
- Application-Specific Robot: The Motoman EA1900N NX100 6-axis robot was chosen for its exceptional speed and dexterity. Providing a 1904mm reach and 3kg payload, this welding robot proved a perfect match. The EA1900N is a member of Motoman's Expert Arc series and equipped with an advanced NX100 controller.
- Welding Power Source: The system was integrated with the Miller Auto-Axcess 675 amp CV/Pulsing power source. The welding dress package includes an air-cooled welding torch, safety holder, and wire feeder.
- 180 Degree Indexer and Weld Table:
Two welding tables, one indexing and the other stationary, were incorporated into the final solution. The two position 180-degree indexer has a 72" tabletop. Its dual stations allow for speedier cycle times. As parts on one side of the table are being welded, operators can load the other side. A steel divider in the middle of the table protects those loading parts from glare. The stationary weld table was positioned behind the robot.
- Operator Station: This central control unit provides easy-access command keys for Start, E-stop, Servo-On, Hold, Re-Start.
- Safety Package: RobotWorx safeguarded the welding cell with a number of features. Hard fencing and two sets of light curtains defined the workcell space. Includes hard fencing, one door interlock, zone ring switch, and 2-sets of light curtains. Arc glare included on arc welding packages.
- Support: RobotWorx' complete robotic systems come with free training and a complete one year warranty covering all parts and service.
