Case Studies / Part Transfer / Automotive Door Support Frames

Motoman Robots Arc Welding and HandlingCycle time: approximately 12 seconds each for the various part styles. Customer plans to standardize on Motoman's robotic solutions for all of their tubular assembly automation.

Project Challenges

  • Provide flexibility to weld two different lengths of automatically fed round tubes made of .005 mm (.125") thick high-tensile steel, and also to add an automatic feeder for square tubes in the future.
  • Identify ± 0.5 mm (.020") tube straightness variance in part and maintain tube orientation with high side of tube up.
  • Minimize use of floor space.
  • Cycle time - 12 seconds or less. Production rate is 2,250 parts per shift with two 7.5-hour shifts per day, for a total of 4,500 parts per day - with four welds on each part.
  • Cost/performance was a primary consideration for vendor selection.

Motoman Robotics Solution

Motoman Robotics provided two highly flexible, dual-process solutions. Each system includes:

  • Invert-mounted 6-axis K10S robot with MRC and custom end-of-arm tooling (mechanical gripper)
  • Dual 6-axis SK6 robots with two MRC controllers
  • Allen-Bradley SLC/500 PLC
  • ToughGun™ 400-amp air-cooled torches with Tweco adapter kits
  • OTC welding package with OTC Turbopulse 350 inverter power source
  • Gantry structure used to invert-mount K10S robot
  • Automatic tube feeder with height sensor to detect tube high side
  • High-speed, AC servo-driven 360° rotating positioner with:
    • Three work stations, each with 465.3-kg (1,026-lb) capacity
    • 2-second positioning time
    • Endless rotation modification
  • Common base for positioner. Separate base for SK6 robot MRCs and welding power sources
  • Outfeed chute for finished part with automatic parts ejector
  • 18 LH and RH sets of custom fixture plates (36 plates total)
  • Six sets of locating fixtures on positioner frame
  • Integrated safety package including: fencing, arc screen curtains, one light curtain, and two safety interlocked gates
Ref: ACS-008
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