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Trabalhadora da construção

Robotic Welding Cells

Concept

COMPACT-WELD cells are characterized by being compact, easy to install (“plug-and-play”), simple to operate and highly flexible.

COMPACT-WELD cells use state-of-the-art robotics and welding technology, with high-precision and repeatable robots and inverter sources with specific synergy curves for each type of application;

Robot programming in COMPACT-WELD cells is easy to understand and does not require extensive technical qualifications; the communication interface between the robot and the welding source allows the adoption of individual welding parameters for each bead or sections of the same bead.

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Built on a monoblock 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.

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Applications

Industries seeking greater competitiveness, through the migration from manual welding to the robotic process;

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;

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Industries from different segments that weld small and medium-sized parts and require production flexibility;

Industries that have already consolidated the robotic welding process and that 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 reduced physical space.

Tubular furniture, chairs, tables, benches, ladders;

Fitness equipment;

Manufacturing of supermarket trolleys;

Subassemblies of tractors, construction equipment, road and agricultural implements;

Subassemblies of exhaust systems and shock absorbers (exhausts), mainly in the aftermarket;

Subassemblies of suspension systems, steering, bodies, seats, instrument panels, pedals, etc.;

Frame and welded subassemblies of bicycles and motorcycles;

Civil construction materials industry, such as steel or aluminum frames and several other applications.

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Cell composition

    Estun Robot: ER8-1450/ ER12-1510/ ER10/20-2000

  • Estun Welding Source: EC 350 / EC 500

  • Welding Device

Cell composition

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Suporte do balancim  de sustentação do cabeamento flexível da tocha (quando aplicável).

Note: The rocker arm, where applicable, is not included in the scope of supply.

  • Tocha Estun: EC 350 / EC 500

  • Robot pedestal

The pedestal facilitates the robot's reach to workstations.

Cell composition

1 or 2 workstations

Portas  de meia altura com janela em policarbonato anti-UV e acionamento pneumático controlam o acesso para carga e descarga, impedindo o contato físico do operador com o robô em movimento e sua exposição ao arco elétrico.

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Cell composition

1 or 2 workstations

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Versions with one or two workstations with a capacity of up to 500 kg: while the robot welds at one station, the operator loads and unloads at the other. The robot doesn't stand still waiting for the operator, maximizing cell productivity.

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Cell composition

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Enclosure

Security closure

in “plate X plate” steel supported by fixed columns, preventing access to the inside of the cell during the welding operation.

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Monoblock base

The monoblock base has shoes for fixing to the floor and allows the cell to be moved from one location to another, without the need to readjust the robot program.

Housings for fitting forklift forks .

Cell composition

Maintenance door

Door with electronic safety interlock: Safety key with electronic lock and bolt, linked to the cell's security system.

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When the door is opened, the

cell equipment is powered

zero level and the robot with the power off (when in automatic mode). A safety fault is then generated. To safely reactivate the system, the "reset" button (on the panel) must be pressed.

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Cell composition

Power and control panel

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Electrical power and control panel, monoblock in 1.9mm sheet metal and electrostatic powder coating in standard RAL 7032 gray, with components mounted on a DIN rail.

Connections made via terminal strip between the panel and the field, and the panel and the door; door and panel structure grounded with cable of appropriately sized cross-section.

Wiring: pre-insulated compression terminals, identification by washers and packaging in gutters.

Pneumatic panel

Composition of the pneumatic panel:

    A FESTO or SMC compressed air preparation and conservation unit, with digital pressure switch;

  • Two 5/2-way directional valves, actuated by a double solenoid, to depressurize the doors when the emergency button is pressed;

  • Space for installing the pressure gauge and protective gas pressure and flow regulator valves.

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Note: The pressure gauge as well as the pressure and shielding gas flow regulating valves are not included in the scope of supply.

Control/operation panels

Visual signaling

Operation buttons, one at each workstation, with two selectors, one to raise and lower the door, in manual mode, the other to select “manual” or “automatic” mode; “start” and emergency buttons, in addition to a light signal to identify the cell ready:

Color indicators to identify the cell's operating status: (1) green indicates that the cell operates in automatic mode; (2) red indicates an active failure or emergency.

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Options, customizations and other services

Options:

Automatic torch cleaner;

  • Metal hood for welding fume extraction

Customizations (upon request):

Part clamping devices;

  • Workstations;

  • External axes of the robot;

  • Weld sensing.

Additional services (upon request):

Transport of the cell to the customer's plant;

  • Qualification of the welding procedure;

  • Robot programming training;

  • Robotic MIG/MAG welding training.

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Advantages:

Security:

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Enclosed welding cell, inside which humans have no access,

  • Reduction or elimination of unhealthiness,

  • Reduction in absenteeism (by reducing unhealthy conditions and human fatigue).

Labor:

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Low labor cost (operators),

  • High availability of labor,

  • Low cost of personnel qualification;

Quality:

    High process repeatability,

  • Lower level of distortion due to reduced heat input to the part,

  • Low rework and scrap rate,

  • Reliability: high value perceived by the end customer;

Productivity:

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High welding speeds,

  • Constant cycle time and OEE above 80%;

  • Lower consumption of wire, shielding gas and electrical energy;

  • Reduction of production costs,

  • Reduction in manufacturing lead time and consequently in delivery times to the end customer;

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