Arc Welding of Electrical Wiring Ducts using Two YASKAWA AR1440 Robots

Industry > MachineApplication > WeldingSector > Manufacturing

This application case features two YASKAWA AR1440 robots specifically designed for arc welding electrical wiring ducts.

By utilizing two welding robots in coordination with a rotating turntable (positioner), the system rapidly performs precise welding at all required joint locations, ensuring high-speed production and structural integrity.

Components

Robot	Robot: YASKAWA AR1440 + Welder Package (2 Units) Type: 6-axis articulated welding robot. Payload: 12kg. Horizontal Reach: 1,440mm. Repeatability: ±0.08mm. Weight: 150kg.

Workflow

STEP 1.	Securing the workpiece onto the welding jig.
STEP 2.	Initiating the work via the operation button.
STEP 3.	Performing the primary arc welding process.
STEP 4.	Positioner Rotation: The turntable rotates to expose the opposite side.
STEP 5.	Performing the secondary (rear-side) welding process.
STEP 6.	Preparation for discharge once welding is complete.

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Key Features

High Operational Efficiency and Quality

Optimized Human-Robot Collaboration: The robots handle tasks requiring consistent quality and high skill levels, while operators focus on material loading and unloading, improving both efficiency and output quality.
Minimized Cycle Times: Rapid arc welding performance significantly reduces the time required for each workpiece.
Superior Weld Quality: Achieves high-precision weld beads, which drastically reduces the need for—and cost of—post-processing and grinding.
Versatile Positioning: By utilizing 6-axis articulated robots in tandem with a positioner, the system can perform complex welds from various angles and positions that are difficult to reach manually.

Implementation Results

ROI Period	1.2 years
Key Metrics	Significant improvement in overall weld consistency and quality. Productivity levels matching or exceeding those of highly skilled manual welders.
Client Feedback	We introduced robots due to the difficulty of hiring skilled welders, and we are extremely satisfied with the high-speed operation and the uniform quality we've been able to achieve.