Welding Cells | Welding | MCK Welding | São Paulo | Brazil
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.
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.
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;
Indústrias de diferentes segmentos que soldam peças de pequeno e médio porte e necessitam de flexibilidade de produção;
Indústrias que já consolidaram o processo de soldagem robotizada e que possuem ciclos de investimentos periódicos (como, por exemplo, as autopeças), mas necessitam reduzir o custo do investimento, através da racionalização das suas especificações técnicas para células robotizadas.
Instituições de ensino que visam capacitar profissionais em alto nível e em curto prazo, utilizando tecnologia de ponta e espaço físico reduzido.
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.
Cell composition
Estun Robot: ER8-1450/ ER12-1510/ ER10/20-2000
Estun Welding Source: EC 350 / EC 500
Welding Device
Cell composition
Rocker arm support for supporting the torch's flexible cabling (when applicable).
Note: The rocker arm, where applicable, is not included in the scope of supply.
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Estun Torch: EC 350 / EC 500
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Robot pedestal
The pedestal facilitates the robot's reach to workstations.
Cell composition
1 or 2 workstations
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.
Composição da célula
1 or 2 workstations
Half-height doors with anti-UV polycarbonate windows and pneumatic actuation control access for loading and unloading, preventing the operator from having physical contact with the moving robot and exposing them to electric arcs.
Cell composition
Enclosure
Security closure
in “plate X plate” steel supported by fixed columns, preventing access to the inside of the cell during the welding operation.
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.
Alojamentos para encaixe dos garfos da empilhadeira.
Composição da célula
Maintenance door
Door with electronic safety interlock: Safety key with electronic lock and bolt, linked to the cell's security system.
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.
Cell composition
Power and control panel
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.
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
Sinalização visual
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.
Options, customizations and other services
Options:
Automatic torch cleaner;
Metal hood for welding fume extraction
Customizations (upon request):
Fixing devices for parts;
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.
Advantages:
Security:
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:
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:
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;
