Cable Tray ARC Welding using Dual Synchronized Panasonic Robots

Industry > Metal·PlasticsApplication > WeldingSector > Manufacturing

This welding automation solution features two Panasonic industrial robots working in perfect synchronization to perform multi-angle welding on long beam structures.

By deploying dual robots to work simultaneously on both sides of the beam and utilizing a dual-jig (front and back) arrangement, the system ensures continuous operation and exceptionally high productivity. The integrated Panasonic TAWERS system enables high-speed welding and superior bead quality. Since the welding power source, robot, and wire feeder are provided as a single unified package, rapid installation and precise tuning are possible.

Components

Robot	Robot: Panasonic TM-1400 (Separate Type) Separate Type Technology: Panasonic’s proprietary design integrates the power and gas cables into the manipulator to minimize environmental interference and ensure highly stable wire feeding. 6-axis articulated robot, payload 6kg, reach 1,437mm, weight 170kg, repeatability ±0.03mm. Welding Power Source: YD-350VR1 Digital control method, 3-phase 50Hz/60Hz, AC 200–220V, weight 48kg.

Robot

Robot: Panasonic TM-1400 (Separate Type)
- Separate Type Technology: Panasonic’s proprietary design integrates the power and gas cables into the manipulator to minimize environmental interference and ensure highly stable wire feeding.
- 6-axis articulated robot, payload 6kg, reach 1,437mm, weight 170kg, repeatability ±0.03mm.
Welding Power Source: YD-350VR1
- Digital control method, 3-phase 50Hz/60Hz, AC 200–220V, weight 48kg.

Workflow

STEP 1.	Loading: The operator secures the beam structure into the welding jig.
STEP 2.	Command: The operator initiates the process by clicking the work instruction button.
STEP 3.	Primary Welding: Both robots perform synchronized welding on the first workpiece.
STEP 4.	Maintenance: The robots execute an automatic wire nozzle cleaning cycle.
STEP 5.	Secondary Welding: The robots move to the second workpiece positioned in the rear jig and perform welding.
STEP 6.	Concurrent Operation: While the robots are welding, the operator unloads finished parts or loads new raw materials into the inactive jig.

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Features

High Operational Efficiency and Quality

Optimized Human-Robot Collaboration: Tasks requiring consistent quality and high skill are performed by the robots, while the operator handles loading/unloading, simultaneously boosting productivity and output quality.

Minimized Cycle Times via Dual-Robot Layout:

Parallel Configuration: Two robots are positioned in parallel to perform simultaneous welding on a single workpiece.
Zero-Downtime Workflow: The efficient layout allows the operator to load new materials or unload finished parts while the robots are actively welding in another zone.

Advanced Motion & Feed Control: Utilizes specialized logic for starting and ending welds to shave seconds off the cycle time.

Auto-Re-ignition Logic: Minimizes downtime by automatically re-attempting arc ignition in the event of an initial failure.

Superior Welding Quality and Reduced Post-Processing Costs

Panasonic Spatter Reduction: Incorporates proprietary technology to drastically reduce spatter and surface cleaning requirements.

Precision Heat Control: Minimizes thermal distortion by managing heat input throughout the process.

Intelligent Sensor Integration:

Gap Sensing: Recognizes the distance between the welding tip and the workpiece to correct for uneven surfaces.
Touch Sensors: Compensates for alignment errors between workpieces.
Arc Sensors: Provides real-time automatic compensation during welding to maintain uniform bead quality.

Simplified Installation and Monitoring

Rapid Deployment: As an integrated system (Robot + Power Source + Controller), no separate interface development is required.

Weld Navigation: Features a user-friendly interface for rapid parameter setting and fine-tuning.

Seamless Synchronized Motion: Enables easy coordination with external positioners or other robots, significantly reducing overall installation and setup time.

Data Management: Simplifies the monitoring and logging of welding performance data for quality assurance.

Results

ROI Period	12 – 14 months
Key Benefits	Massive boost in overall throughput. Significant improvement in welding quality and consistency. Productivity levels rivaling or exceeding highly skilled veteran welders.
Client Feedback	The combination of high-speed welding performance and the ability of two robots to work simultaneously has led to a major increase in productivity. Furthermore, because we can prepare the next workpiece while the robots are busy welding, we've drastically shortened our overall setup and production lead times.