Laser Welding of Round Bars using Yaskawa Robots

Industry > Metal·PlasticsIndustry > MachineApplication > WeldingSector > Manufacturing

This welding automation solution utilizes the YASKAWA GP8 robot to perform high-precision laser welding on round bar products from multiple angles.

Previously, an operator had to manually lift each workpiece, load it into the welding machine, and repeat the process for the opposite side once the first side was finished. This manual sequence has been fully automated using the robot.

Continuous production is now possible regardless of operator availability. By leveraging the fast and precise YASKAWA GP8, the system achieves both guaranteed quality and enhanced productivity.

Components

Robot	Robot: YASKAWA GP8 6-axis articulated industrial robot. Payload: 8kg Horizontal Reach: 727mm Weight: 32kg Repeatability: ±0.02mm (High-precision performance)

Workflow

STEP 1.	Infeed: Workpieces are fed into the system via an infeed conveyor.
STEP 2.	Picking: The robot picks the workpiece from the conveyor.
STEP 3.	Loading & Welding: The robot loads the part into the laser welder and the welding cycle begins.
STEP 4.	Rotation: The robot rotates the workpiece to perform welding on the opposite side.
STEP 5.	Discharge: The completed workpiece is unloaded onto the discharge conveyor.

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Features

Fast and Precise Operation

High-Performance Motion: Utilizes a robot with rapid travel speeds and high repeatability for consistent output.

6-Axis Flexibility: The articulated robot enables welding from various angles and positions, ensuring full coverage of complex geometries.

Custom Design and Pre-Verification

Optimized Tooling: Custom end-of-arm tooling (EOAT) designed and manufactured to meet specific performance requirements.

Operational Flexibility: Provides the adaptability to handle changes in workpiece design, unlike fixed-purpose machinery.

Simulation-Based Validation: Uses 3D simulation to conduct interference checks and verify cycle time performance before on-site deployment.

Results

ROI Period	18 months
Key Benefits	Increased productivity through continuous, non-stop operation. Significant reduction in required manpower.
Client Feedback	We maximized productivity by minimizing idle time. Previously, we were concerned about the lack of flexibility in dedicated machines when models changed, but by adopting a 6-axis articulated robot, we've secured that flexibility. We expect it to be much easier to adapt or upgrade the system when new models are introduced in the future.