Aluminum Storage Tank Welding using Panasonic Welding System

Industry > Metal·PlasticsApplication > WeldingSector > Manufacturing

This welding automation solution utilizes the Panasonic Automatic Welding System (Active-TAWERS) to enable multi-angle welding of aluminum storage tanks.

By incorporating a positioner, the system can flawlessly perform tasks on large structures like silos or in locations that are difficult for human workers to reach. Implementing automation with the Panasonic system allows for the simultaneous achievement of high welding speeds and superior quality. Since the integrated welding system, robot, and positioner are provided as a single package, rapid installation and tuning are possible.

Components

Robot	Robot: Panasonic TM-2000 S-AWP 6-axis articulated robot, payload 6kg, reach 2,011mm, weight 217kg, repeatability ±0.03mm. Welding Power Source: YD-350VR1 Digital control method, 3-phase 50Hz/60Hz, AC 200–220V, weight 48kg. System Integration: Features the Active-TAWERS technology for synchronized wire feed and arc control.

Workflow

STEP 1.	Loading: The aluminum tank components are secured onto the jig.
STEP 2.	Command: The operator initiates the process by clicking the work instruction button.
STEP 3.	Primary Welding: The robot performs the first stage of the welding task.
STEP 4.	Reorientation: The system moves the workpiece or robot to the next welding position.
STEP 5.	Subsequent Welding: Follow-up welding tasks are executed to complete the seam.

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Features

High Operational Efficiency and Quality

Optimized Human-Robot Collaboration: The robot handles tasks requiring consistent quality and high skill, while operators manage loading/unloading, simultaneously boosting efficiency and quality.

Rapid Cycle Times: Minimizes processing time using advanced motion and feeding control logic during the start and end of the welding process.

Auto-Re-ignition Logic: In the event of an arc ignition failure, the system automatically attempts to re-ignite, minimizing downtime caused by errors.

Wide Working Range and Optimal Posture via Positioners

Single Robot Capability: A single robot can perform full welding on large-scale structures.

Difficult Access Areas: Easily executes tasks in locations that are physically challenging or hazardous for human workers to reach.

Superior Weld Quality and Reduced Post-Processing Costs

Spatter Reduction: Applies Panasonic’s specialized technology to drastically reduce spatter and surface smut.

Heat Input Control: Prevents distortion by minimizing heat input into the material.

Automatic Compensation: * Senses the distance between the welding tip and the workpiece to correct for uneven shapes.

Uses Touch Sensors to compensate for gaps between workpieces.
Uses Arc Sensors for real-time automatic compensation during welding to ensure uniform bead quality.

Easy Installation and Monitoring Functions

Fast Setup and Tuning: As an integrated system, no separate interface work is required between the robot and the welder.

Weld Navigation: Simplifies parameter setting and tuning, allowing users to find optimal conditions quickly.

Synchronized Motion: Can be linked with external positioners or other robots for synchronized movement, reducing installation time.

Data Management: Easy monitoring and record-keeping of welding operation data.

Results

ROI Period	12 – 14 months
Key Benefits	Significant improvement in weld quality consistency. Productivity levels equivalent to highly skilled veteran welders.
Client Feedback	For large-scale silos, the structures are so massive that it was difficult for workers to move around, often requiring multiple people for a single task. There were also hard-to-reach areas that posed a real challenge. After introducing J-One Robotics' solution, we were able to solve all these issues with a single robot.