There are always important factors to consider when you are determining what kind of application you want to integrate into your welding system.  As an authorized distributor for OTC Daihen, KC Robotics, Inc. encourages companies to review the guidelines that Daihen has provided.  Their purpose serves as a way to help establish, with a high degree of accuracy, exactly what welding application would be best-suited for your company.

• Current conditions – current welding conditions, equipment problems, and any other relevant information.
• Details about the welding part itself – what is it used for, detailed drawings, and any information on the previous applications.
• Your goals for improving this part – what are your target cycle times, quality specifications, and any other requirements.

Reference:  http://www.daihen-usa.com/applications/

OTC announces the new welding power supply DP400R

The next evolution in welding – A more powerful pulse welding machine

Improved stability and quality for stainless and mild steel welding

KC Robotics is an authorized OTC-Daihen dealer. Contact us now for a first viewing of the new OTC welding power supply.

The All digital, wave-form generation allows you to design special wave forms for pulse welding steel and aluminum.  The Laser seam-tracking option makes more accurate welds than “through the arc” seam tracking.

Benefits of the OTC Welding Power Supply DP400R

• Lower spatter with high speed welding: With an optimized wave pulse method, high quality welds are achieved even with lower voltages during high speed welding.
• Reduced porosity, even with galvanized welding.
• Wider range of stability: This power supply performs stable high quality welding even when the gas mixture ratio is changed.
• Advanced Arc Start Control: “CP-start” provides a smooth arc start and is able to prevent interruption of the weld due to arc start failures.
• Beautiful welding bead appearance: Reduced spatter generation for clean beautiful looking welds.
• TIG like bead appearance with WAVE PULSE II: By controlling the wire feed speed a TIG like bead appearance can be achieved.
• Better gap welding control with WAVE PULSE II: Wave Pulse welding provides better heat control and improves the tolerance to gaps.
• Simple to install on OTC Almega AII robots: The connection between the Almega AII and the D-series power supply is simple when using a CAN interface board (optional).
• Almega AII welding benefits: OTC’s RS control (optional) achieves stable arc starts and reduces spatter with a 4-roll wire feeder. This also helps reduce poor welding due to arc start problems. Also, the OTC Almega AII welding robot series can determine the welding conditions through the teach pendant automatically using given welding conditions (thickness, joint type, weld length, and welding speed).
• Standard warranty 3 years on parts and labor
• The DP400R has an 80% duty cycle at 400 amps and a 100% duty cycle at 350 amps.
• The DP400R can be retrofitted to almost any robot including FANUC, Motoman, and ABB.

OTC Daihen Corporation introduced the new DP400R welding power supply on October 5, 2009 to OTC Suppliers.  It will be available later this year from KC Robotics, Inc. Call or email now to be the first to see a demonstration this new generation of welding power supply.

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