Motoman Robots Arc Welding

Space-saving Motoman welding cell uses four SSA2000T robots controlled by one NX100 QRC robot controller to weld automotive axle crossmembers that are progressively fixtured on two frames located on a three-motor headstock/tailstock trunnion positioner.Automotive Axle Crossmembers

Robot system meets or exceeds project requirements for welding axle crossmembers that include three subassemblies and opposite sides of a final assembly. Robot system achieves 98-second cycle time (including sweep time), which is 5.5-19.7% faster than 103.7-122 second requirement. Robotically welded parts meet customer’s stringent specifications to achieve required automotive quality standards. System provides high-throughput welding cell that minimizes need for skilled manual welders.

Project Challenges

Motoman Robotics Solution

Motoman Robotics provided a modified ArcWorld V-6400XHD with quadruple robot control (QRC), including:

Fixtures/Tooling Details

Motoman Robotics provided two crossmember fixture frames, one per side of the positioner. Each frame includes five sets of custom fixtures; three for welding subassemblies and two for opposite sides of a final assembly. Poke-yoke fixture design prevents parts from being loaded incorrectly into the progressive fixtures that include pneumatic clamping. Various part and clamping sensors are included.