modern concepts for implementing robotic arc … concepts for implementing robotic arc welding terry...
TRANSCRIPT
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Modern Concepts for Implementing Robotic Arc Welding
Terry K. Merrifield, VP/GM MWES, CWI, CRAW-T, CERTSteve B. Wise, Lead Project Engineer, Eaton Power, CWI
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Introduction
Terry Merrifield – VP/GM at Midwest Engineered Systems, Inc.• 27 years of experience integrating robotic automation• AWS D1.1 CWI, CRAW-T• RIA Certified Expert Robotic Technician
• Welding – thin gauge through heavy welding applications• Machine tending, palletizing, material handling• Assembly and deburring
Steve Wise – Lead Project Engineer at Eaton (Cooper Power) • AWS D1.1 CWI• B.S. - Mechanical Engineering • 8 years working at Eaton
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What Will We Cover?
• Reasons to automate
• Modern techniques for robotic welding integration
• Common mistakes
• Sensor technology applications
• Vendor selection criteria
• Keys to successful robotic welding implementation
• Real world examples of challenging process applications & how companies worked to overcome them
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Manufacturing Considerations
Below are a few of the many reasons manufacturers consider implementing welding automation into their process:
• New product or product mix
• Increased productivity
• Quality improvements and traceability
• Ergonomics/safety/job quality
• Increased throughput with reduced labor content
• Lack of experienced/trained welders
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Sustainability
• American companies are brining manufacturing back to the United States
• Automation is an enabler of this trend
• Boosts sustainability locally & abroad
• Creates long-term employment
• Sense of satisfaction with quality products made Pridefully in the United States
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Adopting the Technology
What would you say if your company says they will be introducing welding robots into the operation?
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Adopting the Technology
• U.S. manufacturing disappeared because cheaper manufacturing abroad became a competitor
• Many hidden costs due to the lower quality of replacement components we receive from abroad i.e. welding consumables, part handling, extra robot programming, ect.
• The important role automation plays in manufacturing for the U.S.
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Integrator Selection Criteria
• Selecting the RIGHT integrator is the most important factor for automation success
• Many robotic welding integrators do not keep up with current technology trends & fall short
• Manufacturing must be aligned with corporate goals
• Manufacturing engineers are often at the forefront of the integrator selection process
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Purchasing & Engineering Process
Purchasing and Engineering must work together to discover, learn, and understand current technology
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Automation Buying Decision
• Cost
• Quality
• Performance
• Flexibility
• Process Technology
• Capacity
• Quality System
• Production & Inventory Control
• Workforce Management
• Manufacturing Organization
• Management
• Operations
• Purchasing
• Engineering
• Production
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Purchasing & Engineering Process
Weighted vendor selection criteria
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Purchasing & Engineering Process
• Corporate buyers are expected to make sound spending decisions, and often favor the lowest priced vendor
• Manufacturers often times don’t have exact figures for budgets and are unsure when they will be able to spend
• Depending on complexity, integrators can assist the manufacturer through process development and developing a RFQ
• Integrators must work with Engineering & Purchasing to clarify elements detailed in the RFQ
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Identifying the RIGHT Integrator
• Cheaper solutions may look good on paper, but be weary if the integrator cannot explain why this solution will be successful
• Identify qualified experience in your application. Has this integrator done something similar before?
• Look for experience in hardware, software, and extensive process knowledge
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Identifying the RIGHT Integrator
During the qualification process, make certain the integrator is equip with the minimum capabilities, skills, & experience:
• Design & build capability for robot transport units (RTUs) & multi-axis work-piece positioners
• Familiarity and experience with relevant robot and process technology
• Off-line programming experience starting with full configurations to part programming
• The integrator must have a staff of highly trained and experienced robot and welding experts for your specific application!
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Keys to Success
• Research• Allow time for Process Engineers
to research and understand technologies
• Develop internal robotic / process knowledge• Embrace technology, be involved,
and learn from your integrator
• High Mix / Low Volume• Look beyond high volume
automation
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Modern Techniques for Robotic Welding
Process Application Toolbox should include:
• Offline Package
• Process component capability and flexibility
• Design and build capability
• Heavy welding package
• Sensor technology
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Eaton Power Tank and Corrugate Automated Welding Problem
• Product Design• Optimize for clearance and
ease of manufacturing
• Materials• Cleaner and better materials
for optimal welding (weld wire)
• Machines• Standardize welding machines
(pulse) and lockout settings
• Personnel• Welding procedures• Experience variation
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Eaton Power Tank and Corrugate Automated Welding Concepts
• Manual Welder Variation
• Robotics added a way to eliminate the variation between operators
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Eaton Power Tank and Corrugate Automated Welding Concepts
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Eaton Power Tank Early FixturingConcepts
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Eaton Power Tank Early FixturingConcepts
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Eaton Power Tank Fixture Revised Concept
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Eaton Power Tank Fixture Revised Concept
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Eaton Power Tank Fixture on 3-Axis Positioner Concept
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Eaton Power Tank Cell Concepts
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Eaton Power Tank Cell Concepts
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Eaton Power Tank Cell Concepts
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Eaton Power Tank Cell Concepts
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Eaton Power Tank Cell Concepts
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Eaton Power Tank and Corrugate Reach Study Analysis
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Eaton Power Tank and Corrugate Reach Study Analysis
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Eaton Power Tank and Corrugate Reach Study Analysis
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Eaton Power Tank and Corrugate Reach Study Analysis
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Eaton Power Tank and Corrugate Refined Concepts
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Eaton Power Tank and Corrugate Refined Concepts
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Conclusion
• Automation builds manufacturing sustainability in the U.S.
• Learn about new technology and don’t be fooled by the common misconception that robots take jobs away
• Do your homework before hiring an integrator
• Trust your integrator to recommend the best robot brand and combination of sensors for the application
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Questions and Answers
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Thank you for Coming!