Project Background: Stainless Steel Well Lid Welding Robot Unit (Applied in one of the famous well manufacturer in India)

Customer Requirement:

1. Use robot to replace labor force for welding. Manual loading and unloading of product. One time fixing of the product onto the fixture.

2. Workpiece material: iron steel, wall thickness: 0.8-1.2mm; Size: 300x300mm or 600x600mm

3. The workpiece should be welded alternately on front side and back side and request to reduce the deformation.

4. The front well lid and back well lid will be welded in separate robot. Accept to weld the well lid in several steps.

Solutions:

1. The complete welding robot system includes 2 sets of HS-R6-08 1.4m arm length robot, 2 sets of 350A MIG welding machine, 2 sets of automatic anti-collision welding gun, 4 sets of one-axis vertical rotation positioner, 2 sets of welding gun cleaner, and 4 sets of welding fixtures, etc.

2. In order to guarantee the stability and consistency of welding quality, we suggest to equip with welding gun cleaner device.

3. Automatic welding is carried out by the six-axis robot MIG welder. The cylinders or fast clamps are used to fix the position of the product with the lever principle to ensure the positioning requirements of automatic welding of the robot, so as to ensure that it can be welded to each part of the product. According to the requirements of production efficiency, two sets of one axis positioner are designed, one for loading and unloading of the workpiece, one for welding.

Workflow:

1) Manual loading of the workpiece to the fixture in Station 1 positioner;

2) Start welding;

3) The robots and welding machines will do welding on the workpiece according to the presetting program;

4) Welding completed;

5) While the station 1 is being welded, station 2 is being loaded and unloaded the work piece synchronously.

6) Cycle working

Application Effect

1. The double-station positioner layout can realize long time continuous welding, welding efficiency and welding quality has been significantly improved;

2. The positioner realizes the workpiece clamping at one time, and automatically realizes the alternating welding of the four corners of product, the deformation is effectively controlled.

3. This machine can achieve automatic welding with manually loading material. It can also improve the welding quality and welding efficiency. Whats more, it can reduce the production cost. The problem of unstable quality and low production efficiency caused by pure manual operation has been solved.

4. Robot replace manual welding. Welding industry is a high-risk industry, high temperature, arc light and welding smoke have a certain impact on the physical and mental health of workers;

5. It is an inevitable trend to use robots to replace welding robots in welding, which is not only the promotion of the market, but also the requirement of technological upgrading.