Project Summary:

A manufacturer of industrial valves came to KC Robotics to find a cost effective 8 axis robotic solution. The company’s overall goal was to integrate the robot in a laser cladding application.

Application Goals:

• Work Envelope: The customer required a large work envelope to accommodate the laser cladding process of their part.
• Tilt / Rotate Table: The customer required a tilt rotate table to adequately access their part.
• Rotate: The process dictates that we rotate their part up to 25 RPM continuously throughout the process.

KC Robotics Work Cell Details:

FANUC  Arcmate 120 RJ2 with Aux Axis Package – A reconditioned 6 axis robot with 16kg payload and 1667mm of reach outfitted with an auxiliary axis package featuring 2 additional axes of movement.

Fanuc Powermate Controller – We utilized a FANUC powermate CNC controller to control the rotational axis of the tilt rotate table. This allowed us to continuously turn the rotational axis at 25 RPM.

Troyke: KC robotics utilized a Troyke TIL-25-C tilt rotate table for the external axis’s to drive.

Operator interface – Push button interface with Start, Hold, Reset and E-stop.

Project Case Study:

An air management company required an automated aluminum welding solution for a new product they were developing. KC robotics worked with the customer to develop a cost effective turnkey robotic solution utilizing a reconditioned FANUC robot, OTC Daihen welding power source, and Allen Bradley controls.

Application Goals:

• Weld Quality: The FANUC Arcmate 120i utilizing an OTC Daihen DP-400 power source provides a high quality and reliable aluminum welding process.
• Rotary Axis: In order to position the parts so that each weld is in the flat, KC Robotics utilized an Allen Bradley Control logix processor as well as a Kinetics drive unit to actuate a rotary axis.
• Work holding/Fixturing: Customer required a workholding solution in addition to the robot
• Controls: The Customer utilizes Allen Bradley controls as a plant standard and requested a touch panel HMI for operator interface and control.
• Safety: A complete safety system including hard fencing with a sliding door, safety interlocks, and Keyence light Curtains.

KC Robotics Work Cell Details:

FANUC Arcmate 120i RJ2 – a reconditioned 6 axis robot with 16kg payload and 1667mm of reach
OTC Daihen DP-400 – New 400amp pulse welding power supply sports industry-leading pulse welding schedules for a variety of metals and thicknesses, including aluminum and brazing.

Operator interface – Allen Bradley Panel View 600 with Start, Hold, Reset, and E-Stop pushbuttons.

Safety Package – 1 set of Keyence SLV-HM series light curtains with Safety Relay. Door interlocks and solid panel fencing to protect the operator and other workers from both arc flash and entering the robot work area.

Work holding – A custom welding jig to accommodate fast and easy part changes as well as family changes. Includes a heat sink to help prevent part from warping during the welding process.

Links / References: Allen Bradley, Keyence, OTC-Daihen