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robotics

Robotic Steel Welding

Robotic Steel Welding

Here is a great example of a steel welded assembly at Lean Machine.  It's a steel ring with a strengthening rib welded on.  As the demand for this part has increased we've applied our standard thinking: if an employee is going to do the same repetitive task over and over (and most likely get extremely tired of doing so) then we need to find a better way to accomplish the task.  Our Motoman/Fronius robotic welding cell is always happy to help us automate.

Step 1- Design and build a jig assembly that can make part placement repetitive and accurate.  We've used the Motoman positioner in conjunction with the robot to help keep weld angles consistent.  Consistent weld angles give us good flux gas (CO2/Argon mix) coverage to make sure welds are not contaminated with atmospheric impurities. 

Step 1- Design and build a jig assembly that can make part placement repetitive and accurate.  We've used the Motoman positioner in conjunction with the robot to help keep weld angles consistent.  Consistent weld angles give us good flux gas (CO2/Argon mix) coverage to make sure welds are not contaminated with atmospheric impurities. 

Step 2 - Make the parts themselves better to help with the whole process.  Here you can see slots in the ring so the rib can index itself with tabs.  On the surface, these parts would be much cheaper to produce out of steel flat-bar but we've decided to laser cut them so we can tightly control tolerances on hole sizes and add trick tab and slot features.

Step 2 - Make the parts themselves better to help with the whole process.  Here you can see slots in the ring so the rib can index itself with tabs.  On the surface, these parts would be much cheaper to produce out of steel flat-bar but we've decided to laser cut them so we can tightly control tolerances on hole sizes and add trick tab and slot features.

Step 3 - Write a really great robotic welding program in RobotMaster.

Step 3 - Write a really great robotic welding program in RobotMaster.

Step 4 - Run off parts as quickly as possible!

The resulting weld bead has a good start, nice bead size, proper penetration, and a great crater fill.  With all of the parameters available in the Fronius welders you can "tune out" and splatter so the parts need zero clean-up after the weld process and zero anti-splatter coating.

The resulting weld bead has a good start, nice bead size, proper penetration, and a great crater fill.  With all of the parameters available in the Fronius welders you can "tune out" and splatter so the parts need zero clean-up after the weld process and zero anti-splatter coating.

Welding and labour continuous improvement

Welding and labour continuous improvement

Every single day at Lean Machine we work hard to make our customer's parts look better.  Also, we need to continually drive down our internal labour costs.  Our favorite type of part to improve and automate are the repetitive ones.  Every time we are able to automate a process we can re-purpose an employee's position to do something more interesting or increase our capacity.  Below you will find a video of robotic welding on aluminum landing gear as well as some before and after pictures of manual versus robotic processes.

A manual weld on a large arc between 3/8` and 1/8`aluminum plate.  This is a great example of a solid manual aluminum weld using Fronius welding equipment.  This weld is challenging because the employee has to re-position themselves several times to make sure the correct torch angle is achieved as they move around the arc to ensure the shielding gas is protecting the leading edge of the weld pool.

A manual weld on a large arc between 3/8` and 1/8`aluminum plate.  This is a great example of a solid manual aluminum weld using Fronius welding equipment.  This weld is challenging because the employee has to re-position themselves several times to make sure the correct torch angle is achieved as they move around the arc to ensure the shielding gas is protecting the leading edge of the weld pool.

Here is the after picture of the same parts welded together but using an automated robotic welding cell.  The weld has a bit more shine to it mostly due to the perfect torch angle being achieved by the robot`s perfect welding program made directly out of our CAD models.  The weld bead size is also perfect every time. 

Here is the after picture of the same parts welded together but using an automated robotic welding cell.  The weld has a bit more shine to it mostly due to the perfect torch angle being achieved by the robot`s perfect welding program made directly out of our CAD models.  The weld bead size is also perfect every time.