Process layout
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 |
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Workflow
| STEP 1. | Loading: The operator secures the beam structure into the welding jig. |
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| 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. |
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
| Key Benefits | Massive boost in overall throughput.
Significant improvement in welding quality and consistency.
Productivity levels rivaling or exceeding highly skilled veteran welders.
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| 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. |
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