Process layout
This welding automation solution utilizes the Rainbow Robotics RB-3 collaborative robot combined with a TIG welder to weld the bended sections of metal plates. It is characterized by fast teaching capabilities and high space efficiency.
In manual welding, quality varies significantly based on the operator's skill level. Additionally, due to the harsh working conditions, securing skilled welders is becoming increasingly difficult.
With this solution, even unskilled workers can manage the loading and unloading of workpieces, while the robot handles the critical welding tasks. This ensures consistent, high-quality production regardless of human fatigue or skill level.
Components
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Workflow
| STEP 1. | Loading: The operator fixes the workpiece to be welded into the specialized jig. |
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| STEP 2. | Execution: The operator clicks the "Work Start" button on the interface. |
| STEP 3. | Welding: The robot performs high-precision TIG welding along the corner edges of the bent plate. |
Features
Enhanced Efficiency & Quality through Human-Robot Collaboration
Optimized Task Distribution: The robot handles high-precision tasks requiring consistent quality and high skill levels, while the operator focuses on loading and unloading workpieces. This synergy simultaneously boosts both operational efficiency and product quality.
Uniform Performance: Eliminates human error and fatigue, ensuring that every weld meets a professional standard.
Intuitive and Rapid Teaching
Direct Teaching: Operators can manually move the robot arm to set welding paths, making the process intuitive even for those without programming experience.
Rapid Changeover: Even when the production model changes, additional teaching can be completed within 10 minutes.
User-Friendly Interface: The Android-based tablet teaching pendant allows users to easily download and use apps, significantly lowering the barrier to entry for robot operation.
Optimized for Harsh Welding Environments
Superior Durability: The high IP66 rating protects internal components from damage caused by dust, metal filings, and high-pressure sparks typical in welding zones.
Space Efficiency: The compact and lightweight design of the small collaborative robot minimizes the footprint required, allowing it to fit into tight production lines.
Results
| Key Benefits | Quality: Drastic reduction in defect rates through precision arc control.
Productivity: Achieves a production tempo equivalent to a highly skilled veteran welder without the need for breaks.
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| Client Feedback | It was incredibly difficult to find and retain skilled welders even trained workers often left once they gained experience. By introducing robot automation, we've secured uniform quality and stabilized our production, which has been a massive help to our business.
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