.png){kind=small}
MIG/MAG welding
Concept
COMPACT-WELD cells are characterized by being compact, easy to install ("plug-and-play"), simple to operate, and highly flexible.
COMPACT-WELD cells utilize state-of-the-art robotics and welding technology, featuring high-precision and repeatability robots and inverter power sources with synergy curves specific to each type of application;
Programming the robot in COMPACT-WELD cells is easy to understand and does not require extensive technical skills; the communication interface between the robot and the welding power source allows for the adoption of individual welding parameters for each weld bead or sections of the same weld bead.
Built on a monobloc base, COMPACT-WELD cells allow for agile layout changes: they can be moved by forklifts without the need for disassembly, preserving the robot program, welding parameters, and therefore the already qualified welding procedure.
Applications
Industries seeking greater competitiveness through the migration from manual welding to robotic processes;
Industries that weld structural steels, low-alloy and/or non-ferrous alloys and use MIG/MAG welding processes with solid (GMAW) or tubular (FCAW) wires;
Industries from different sectors that weld small and medium-sized parts and require production flexibility;
Industries that have already consolidated the robotic welding process and have periodic investment cycles (such as auto parts), but need to reduce investment costs by streamlining their technical specifications for robotic cells.
Educational institutions that aim to train professionals at a high level in a short period of time, using cutting-edge technology and a reduced physical space.
Tubular furniture, chairs, tables, benches, ladders;
Gym equipment (fitness);
Manufacturing of supermarket trolleys;
Subassemblies of tractors, construction equipment, road and agricultural implements;
Subassemblies of exhaust systems and shock absorbers (exhaust pipes), mainly in the aftermarket;
Subassemblies of suspension, steering, bodywork, seats, instrument panel, pedals, etc. systems;
Frames and welded sub-assemblies of bicycles and motorcycles;
Construction materials industry, such as steel or aluminum window and door frames, and various other applications.
Cell composition
Estun Robot: ER8-1450/ ER12-1510/ ER10/20-2000
Estun Welding Source: EC 350 / EC 500
Welding Device
Cell composition
Support for the flexible torch cable mounting arm (when applicable).
Note: the rocker arm, when applicable, is not included in the scope of supply.
-
Estun Torch: EC 350 / EC 500
-
Robot pedestal
The pedestal facilitates the robot's reach to the workstations.
Cell composition
1 or 2 workstations
Versions with one or two workstations with a capacity of up to 500kg: while the robot welds at one station, the operator loads and unloads at the other. The robot does not remain idle waiting for the operator, maximizing cell productivity.
Cell composition
1 or 2 workstations
Half-height doors with anti-UV polycarbonate windows and pneumatic operation control access for loading and unloading, preventing physical contact between the operator and the moving robot and their exposure to the electric arc.
Cell composition
Enclosure
Security lock
Made of steel "sheet on sheet" supported by fixed columns, preventing access to the interior of the cell during welding operations.
Monobloc base
The monobloc base has feet for fixing it to the floor and allows the cell to be moved from one location to another without having to readjust the robot's program.
Housings for attaching forklift forks .
Cell composition
Maintenance door
Door with electronic safety interlock: Safety key with electronic lock and "bolt", connected to the cell's safety system.
When the door is opened, the
The cell's components retain energy.
Level zero and the robot with the power off (when in automatic mode). A safety fault is then generated. For safe reactivation of the system, the "reset" button (on the panel) must be pressed.
Cell composition
Power and control panel
Electrical power and control panel, monobloc construction made of 1.9mm thick sheet metal with electrostatic powder coating in standard RAL 7032 gray, with components mounted on a DIN rail.
Connections made via terminal block between the panel and the field, and between the panel and the door; door and panel structure grounded with cable of appropriately sized cross-section.
Cabling: pre-insulated compression terminals, identification by ferrules and housing in cable trays.
Pneumatic panel
Pneumatic panel composition:
Two 5/2-way directional valves, actuated by a double solenoid, for depressurizing the doors when the emergency button is pressed;
Space designated for the installation of the pressure gauge and regulating valves for the pressure and flow of the protective gas.
A FESTO or SMC compressed air preparation and storage unit, with a digital pressure switch;
Note: the pressure gauge, as well as the pressure and flow regulating valves for protective gas, are not included in the scope of supply.
Control/operation panels
Visual signaling
Operating buttons, one at each workstation, with two selectors: one for raising and lowering the door in manual mode, and another for selecting "manual" or "automatic" mode; "start" and emergency buttons, plus a light indicating a ready cell.
Color indicators to identify the cell's operating status: (1) green indicates that the cell is operating in automatic mode; (2) red indicates a fault or active emergency.
Optional extras, customizations and other services
Optional:
Metal hood for exhausting welding fumes.
Automatic torch cleaner;
Customizations (upon request):
Workstations;
External axes of the robot;
Welding sensing.
Devices for securing parts;
Additional services (upon request):
Welding procedure qualification;
Robot programming training;
Robotic MIG/MAG welding training.
Transporting the cell to the customer's plant;
Advantages:
Security:
Reduction or elimination of unhealthy working conditions.
Reduction of absenteeism (through reduction of unhealthy working conditions and human fatigue).
Enclosed welding cell, inside which humans have no access.
Labor:
High availability of labor,
Low cost of staff training;
Low labor costs (operators),
Quality:
Lower distortion levels due to reduced heat input to the part.
Low rate of rework and scrap.
Reliability: high perceived value by the end customer;
High process repeatability,
Productivity:
Constant cycle time and OEE above 80%;
Lower consumption of wire, shielding gas and electricity;
Reducing production costs,
Reducing manufacturing lead time and consequently delivery times to the end customer;
High welding speeds,