ARC Welding Automation for Automotive Cargo Bed Underside using Panasonic Welding System

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ARC Welding Automation for Automotive Cargo Bed Underside using Panasonic Welding System

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Application Field: Industry > Automotive, Application > Welding, Sector > Manufacturing

Industry > AutomotiveApplication > WeldingSector > Manufacturing

#ArcWelding#WeldingAutomation#PanasonicWelding#TM2000#Positioner#LinearTrack#HeavyStructureWelding#QualityImprovement

Process Overview

This welding automation solution uses the Panasonic automatic welding system (TM-2000) combined with a positioner to perform underside welding on automotive cargo beds weighing over 1 ton. A robot travel axis (linear track) is applied to cover a wide working envelope.

By applying the Panasonic automatic welding system, the solution enables both high welding speed and high welding quality for arc welding automation.

In addition, the welding machine, robot, and positioner are configured as an integrated package, enabling fast installation and tuning.

Components

Robot	Panasonic TM-2000 S-AWP 6-axis articulated robot Payload: 6 kg Repeatability: ±0.03 mm Working range: 2,011 mm Weight: 217 kg Welding power source (YD-350VR1) (shared for 3-phase 50Hz/60Hz, digital control method, AC 200–220V, 48 kg)
Peripherals	Robot travel axis (linear track) Workpiece fixing jig and positioner Gas welding machine Work instruction switch box

Workflow

STEP 1.	Fix the weld target workpiece on the jig
STEP 2.	Click the work instruction button
STEP 3.	Perform arc welding
STEP 4.	Click the work instruction button to change the fixing position (positioner rotation)
STEP 5.	Perform subsequent arc welding

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Features

High Work Efficiency and Quality

Assigns tasks requiring consistent quality and skill to the robot, while operators focus on loading and unloading, improving both efficiency and quality
Minimizes cycle time through high-speed welding execution
Reduces cycle time by applying logic and teaching strategies for corner-cutting and fitting motions at welding start and end
Enables automatic re-ignition logic in case of arc ignition failure to minimize downtime due to errors
Secures a wide working range and flexible welding postures by utilizing a positioner
Performs full welding coverage on large structures using a single robot
Enables easy welding in hard-to-reach positions that are difficult for operators
Secures high welding quality and reduces post-weld rework costs
Applies spatter reduction technology
Applies heat input reduction technology
Enables automatic compensation for uneven surfaces by detecting the distance between the welding torch and the workpiece
Enables gap correction using contact sensors
Ensures uniform welding quality by applying arc sensors with automatic compensation during welding

Easy Setup and Monitoring

Provides simple installation and monitoring functions
Enables fast installation and tuning
Eliminates the need for separate interface work by using an integrated welding system package
Enables fast parameter setup and easy tuning using WELD NAVIGATION
Secures various welding postures by linking with an external positioner
Shortens installation time by performing synchronized motion with other robots
Enables easy monitoring and record management of welding process data

Results

Key Benefits	Improved welding quality Increased productivity comparable to skilled operators
Client Feedback	For welding operations, it has become difficult to hire qualified workers, and even when training foreign labor, it still takes time to reach a skilled level. Through welding automation, we were able to perform consistent-quality welding and significantly improve productivity.

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