Aluminum Arc Welding

Aluminum Arc Welding Case Study

Project Challenges

  • Provide a flexible robotic welding system to automate welding of new designs of fence posts and gates.
  • Provide a complete turnkey robotic welding system that is able to accommodate xx variations of parts with minimal tooling change over.
  • Large awkward parts consist of .250” aluminum welded to .060” aluminum tube and .020” wall tube welded to .125” aluminum extrusions.
  • Each gate requires up to 28 individual welds.
  • Improve productivity and shorten lead time
  • Reduce dependency on offshore suppliers
  • Make aesthetically pleasing welds on the outside of the fence post and foot that do not need to be ground down prior to painting.
  • Outside surface condition and visual condition from the weld joint on the inside mounting plate is critical.

KC Robotics Solution

KC Robotics provided a pre-engineered welding system, KCR Systems 300 cell including:

  • KUKA KR16 L6 Robot, an extended reach robot with controller and base riser
  • (2) 500kg headstock / tailstock positioners
  • Fronius TPS GMAW digital welding power supply, integrated welding package with 500A
  • bulk wire feeding system
  • Automatic wire cutter and torch reamer
  • (2) operator station (one per welding station). Functions: Cycle Start, Emergency Stop, Hold, Alarm Reset
  • System Safety Package, including Safety fencing, light curtains, safety interlocked access gates. Meets ANSI/RIA R15.06-2012 standard.

Fixtures / Tooling Details

KC robotics provided manually operated welding fixtures for the fence post welding operation that is able to accommodate 5 posts per cycle.

KC Robotics provided a welding fixture that combined both manual and automatic clamping for the gates. The fixture was designed and built for a quick changeover to 3 different styles and 4 sizes within those styles.

Project Results

  • The robot system meets or exceeds all the project goals. It allows the customer to build the parts needed for the product launch in house in one shift and have the additional capacity for future growth.
  • The system requires 1 operator vs 4-6 skilled welders.
  • Flexible system accommodates several models and allows large and small batch runs with easy changeover.

KC Robotics’ Jack Justice to Speak at RIA Webinar – Robotic Welding Tools, Tricks, Accessories and End of Arm Tools

Join KC Robotics’ Jack Justice as he is a panelist for Thursday’s RIA Welding Webinar. Jack has a broad range of experience in robotics and welding. With over 38 years’ experience in the automation industry, Jack has held positions in welding, systems engineering, sales and project management.

Hear Jack’s ideas on robotic welding

Jack joined KC Robotics in 2014 as General Manager. Jack’s knowledge of robotics and his contacts in the robotics industry have been instrumental in advancing KC Robotics’ Systems Integration division. Under Jack’s leadership, the company has established a professional project management and engineering department, increased sales of integrated systems, and developed relationships with OEM’s.

Robotic Welding Tools, Tricks, Accessories and End of Arm Tools

ABOUT THIS WEBINAR

Date & Time: June 22, 2017, Noon – 1 PM ET

Welding robots are one of the most heavily used robots found in factories. We check in with industry experts to find out what’s changed and the latest and greatest trends in EOATs to push robot efficiency and effectiveness.

Register for this webinar to watch it on or after June 22.

KC ROBOTICS INTRODUCES ULTRASONIC TRIMMING

KC Robotics introduces Ultrasonic Trimming with advanced robotic cutting and trimming technology.  KC Robotics’ Ultrasonic Trimming Cells will include a high-speed Yaskawa Motoman robot, fully integrated with NSK’s ultrasonic cutting tool and milling head.

NSK Unique Technology

  • Cutting tool features a HSS carbide blade vibrating at 40 kHz
  • 7th axis tool
  • control ball
  • navigation tool
  • specialty blade profiles
  • long ultrasonic blades
  • blade sharpening station
  • Compliance blace shape

Ultrasonic Robotic Trimming & Cutting Applications

Ultrasonic cutting offers a unique, environmentally-friendly replacement of waterjet and laser cutting for non-metallic materials, including plastics, foam, carpet, rubber, fiberglass and non-woven fabrics. The technology is ideal for low pressure mold processing, instrument panels and post-process molded part trimming.

Benefits of Ultrasonic Trimming 

  • Enhanced precision – improved trim quality
  • High Speed cutting
  • Cutting forces reduced by about 75%
  • Productivity of cutting process improvement
  • Reduced operating costs
  • Small footprint
  • Lean operation
  • Energy efficient
  • Clean and Eco-Friendly

AUTOMATE 2017

KC Robotics will introduce the Ready-Trim Eco Cell at AUTOMATE 2017 in Chicago, April 3-6. The booth will feature both traditional routing and ultrasonic cutting & trimming. In one cell, a Yaskawa Motoman MH50 II – DX200 Robot and Controller will demonstrate traditional routing on ATV parts. In a separate cell, a Yaskawa Motoman MH24 – DX200 Robot and Controller utilizing NSK technology will provide live ultrsonic cutting and trimming on an assortment of materials.