National Robotic Arc Welding Conference Joy Global Welding Automation June, 2013 Ryan Cross: Principal Manufacturing Engineer-Automation Bryan Hackbarth: Weld Engineering Manager
Small Component Automation Value Stream PHOTO OF AUTOMATION CELL 2 5th June 2013 Robotic Arc Welding Conference
Small Component Automation Cell Typical Weldments 9,000 lbs. 195 x 47 x 46 6,500 lbs. 85 x 56 x 45 17,000 lbs.. 142 x 101 x 69 6,000 lbs. 65 x 51 x 62 12,000 lbs. 98 x 85 x 54 6,000 lbs. 146 x 33 x 62 19,500 lbs. 210 x 47 x 58 3 5th June 2013 Robotic Arc Welding Conference
Small Component Automation Cell Tooling Assemblies Tooling assemblies used to secure weldments to the universal tooling table 4 5th June 2013 Robotic Arc Welding Conference
Small Component Automation Tooling PHOTO OF TOOLING AREA 5 5th June 2013 Robotic Arc Welding Conference
Small Component Automation Cell Universal Tooling Table Tooling is placed on the table with part lifted on and securely fastened to the table prior to loading onto the SmartDock. Alpha-Numeric Grid 6 5th June 2013 Robotic Arc Welding Conference
Small Component Automation Cell Part Preparation After Set-up prior to Automation, weldments brought into prep area to have tacks ground and joints inspected prior to loading onto Universal Tooling Table. 7 5th June 2013 Robotic Arc Welding Conference
Small Component Automation Cell Part Loading Weldment secured to universal tooling table 24,000 lbs. 60 x 120 x 120 8 5th June 2013 Robotic Arc Welding Conference
Small Component Automation Cell Tooling Assemblies 9 5th June 2013 Robotic Arc Welding Conference
Small Component Automation Cell Weldment On Positioner Tooling Table is secured to 20,000 KG positioner via SmartDock. 10 5th June 2013 Robotic Arc Welding Conference
Automation Process Development Benefits of Off Line Programming Reach Study Optimize equipment for the application prior to purchase. Speed Develop and implement programs quickly and efficiently. Validation Simulate program execution and debug before implementing eliminating downtime. Accuracy Develop paths through difficult to reach welds without risking damage to the robot system. Flexibility Allows the programmer to quickly access multiple neck variations, position variations, and robot configurations to create the most robust program. Feasibility Studies Evaluate automation viability of weldments based on geometry, seam configurations and part orientation with minimal investment of resources. Allows early identification of critical or difficult welds and improved design for manufacture and improved tool design. 11 5th June 2013 Robotic Arc Welding Conference
Automation Process Development Off Line Programming Reach studies 12 5th June 2013 Robotic Arc Welding Conference
Automation Process Development Weld Lab Developmental Cell 13 5th June 2013 Robotic Arc Welding Conference
Development of robotic welding procedures 14 5th June 2013 Robotic Arc Welding Conference
Automation Process Development Weld Lab Developmental Cell Activities Weld process development GMAW/MCAW, Pulse, Non Pulse Consumable evaluations GMAW/MCAW, Shielding gas Weld procedure qualification tests GMAW/MCAW, CJP/PJP/Fillet Welds Weld torch mount/neck configurations Custom designed configurations by vendor Program/software development and validation Programming software for large, multiple pass welds on irregular shaped weld joints Training Robot and Cell Maintenance Develop new technology Preheating, Weld Finishing, Tandem Wire, SAW, Inspection 15 5th June 2013 Robotic Arc Welding Conference
Multiple Pass Horizontal Fillet Welds Approximately 43 weld passes 16 5th June 2013 Robotic Arc Welding Conference
Torch Neck Changer Custom designed torch neck changer to handle wide variety of different size necks required for each weldment. 17 5th June 2013 Robotic Arc Welding Conference
Custom Designed Torch Neck Extended reach torch neck allows access to hard to reach locations. 18 5th June 2013 Robotic Arc Welding Conference
Automation Team People make the difference Automation Cell Operator Part Preparation After Set Up Loads and Unloads Cell, Finish Welding/Inspection Welding Technician Supports Automation Cell Operator Attends and resolves weld fault messages Welding Engineer-Automation Conducts procedure qualification tests Evaluates/Implements new weld processes and technology Automation Engineer John F. Hinrichs Create, modify and execute complex robotic welding programs Conducts design reviews for future applications Plan and organize CI projects to reduce cycle time Plan, organize, and deliver training on robotic welding operations Responsible for robotic weld quality 19 5th June 2013 Robotic Arc Welding Conference