Motoman Robots Arc Welding Boom-Lift Grames for Off-Road Vehicles
Heavy-deposition GMAW welding system includes dual Motoman SK16 robots with a single MRC controller.
Summary
Cycle time 1.5 hours per part. Motoman's robotic solution provides a nearly 80% time savings, plus labor savings over manual welding that requires one welder six to seven hours.
Project Challenges
- Need to increase productivity to meet higher volume requirements, but difficult to find skilled welders.
- Heavy-Deposition GMAW welding on eight frame models that are 3,048 mm - 3,658 mm (120"-144") long and 1,067 mm -1,829 mm (42"'-72") wide, and weigh 1,587-1,996 kg (3,500-4,400 lbs) each.
- Manual welding takes one skilled welder six to seven hours per part.
- Manual assembly and pre-tracking requires two hours and part fit-up is not always good.
Motoman Robotics Solution
Motoman Robotics provided a flexible welding solution, including:
- Dual SK16 robots with single MRC-UL controller
- Headstock/tailstock (HS/TS) part positioner with 1,361-kg (3,000-lb) capacity each; 2,721-kg (6,000-lb) capacity total. Adjustable spanners between HS and TS accommodate different models
- 15.2-m (50-ft) servo track with separate carriages for HS/TS
- Operator station
- Two 600-amp water-cooled torches
- ComArc III seam tracking with 200-V high-speed Touch Sense Package
- Two Customer supplied power sources with interface
- Nozzle reamer with anti-spatter sprayer
- Integrated work cell protection package, including wire safety fence, light curtains at load/unload zones, and four safety-interlocked gates
Fixtures/Tooling Details
Motoman Robotics provided the holding fixtures on the HS/TS faceplates used to locate the frames on the positioner. Length of spanners between faceplates is adjustable to accommodate various frame sizes.
