Motoman Robots Arc Welding Semi Trailer Axles

Summary

Average cycle time is approximately 70 seconds for total cycle, 65 seconds for welding portion. Motoman's automated system produces over 300 parts per 8-hour shift. This is more than a 200% improvement over 150 parts per shift produced using the existing robotic welder, and more than five times faster than the 60 parts per shift welded manually.

Project Challenges

• Greatly improve production rate of 150 parts per shift using robotic welding and 60 parts per shift per manual welder.
• Fully automatic system - no operators required, except for initial program selection and to deliver parts at 30-minute intervals via forklift.
• Flexible system required to handle a variety of parts 2,057 mm - 2,209 mm (81" - 87") long, weighing 72.5 kg - 104.3 kg (160-230 lbs) each, with walls of .020 mm - .025 mm (.5" - .625") thick mild steel.
• System must be able to handle full pallets and some configurations

Motoman Robotics Solution

A flexible, fully automated material handling and welding system with custom pneumatic fixturing, including:

• S604 robot with ERC controller
• NY170 robot with MRC controller
• ArcWorld™ 6200 solution, including: - Dual SK6 robots controlled by single MRC - MRM2-250 ferris wheel-type headstock/tailstock positioner - Two Miller Deltaweld 652 power sources, and Robotic II microprocessor-controlled welding interfaces - Two Motoman 450-amp, water-cooled ToughGun™ welding packages, including: torch, safety clutch, wire feeder, side-mount process package, and start-up kit - Two Binzel™ torch reamers - Tregaskiss anti-spatter sprayer- 200-V Touch Sense Package
• Steeplechase PC-based software package running on Visual Logic Controller (VLC). VLC uses Allen- Bradley Touch Screen for Man/Machine Interface (MMI).
• Steel base to elevate all controls 457 mm (18") off floor n Powered infeed/outfeed conveyor for axles/dunnage
• Powered infeed/gravity outfeed conveyor for bracket dunnage
• Bracket nesting station with pneumatically actuated bracket rotation and flip-up components
• Part orientation station
• Pneumatic stand for part dunnage
• Separate custom-designed dunnage for parts
• Integrated safety package, including: fencing, arc screen curtains, photo eyes, and double interlocked gates