The cabinets manufactured in the old Chambery facility had been spot welded and riveted so when MIG welds were specified for the new range, to improve rigidity, robots were an obvious decision to ensure consistency of quality. Automation of all processes is evident in the new facility with manual input restricted to handling and packaging tasks.
Initially two systems were installed by system integrator Air Liquide Welding – automation division (ALW, formerly Commercy Soudure) – to manage both high and low volume throughput. When a decision was made to further automate the welding and handling of higher volume components, proposed solutions were received from four European system integrators.
After a long period – almost two years of investigating solutions offered - Air Liquide Welding was selected again to supply a solution. Mr Maurin, Application Engineer, Schneider, explains, “We took a long time to understand what was needed and the best way to implement it – ALW spent a lot of time with us helping to develop the right solution for our production needs. We built a good working relationship and this gave us the confidence to go with them.”
ALW was able to provide confidence in its proposed solution by demonstrating the cell’s operation using FANUC Robotics’ ROBOGUIDE simulation software. Before placing the order Schneider were able to see the system working in a real-time simulation.
The handling robot was unique to ALW‘s proposal and the simulation was able to illustrate its effectiveness and, importantly, its ability to manage in the very limited space available.
AIR LIQUIDE WELDING SPENT A LOT OF TIME WITH US HELPING TO DEVELOP THE RIGHT SOLUTION FOR OUR PRODUCTION NEEDS.
Schneider’s new welding system has been initially geared up to weld volume production items – cabinet frames. The system comprises three robots – two FANUC Robotics Arc Mate 100iB welding robots and one FANUC R-2000iB/125L robot for unloading and palletising welded frames.
The two welding robots are positioned in an elevated position above a rotating work positioner. A single operator of the cell is responsible for loading components into tooling on the positioned table and actuating the weld sequence when he is out of the loading area.
At this point the welding robots, when they have completed welding the frame, signal the positioner to rotate through 180°. This presents the unwelded components to the robots and also signals the FANUC R-2000iB robot to unload the welded frame from the tooling. The FANUC R-2000iB robot then stacks the completed frame onto a transit pallet which when fully stacked is driven out of the weld system on power rollers.
Further complimenting the cell and meeting the automation objectives of Schneider, the weld cell communicates with an AGV (Automated Guided Vehicle) which collects the full pallet from the power rollers and takes it to the next operation in the process.
The two welding robots are controlled through the same FANUC Robotics control system using FANUC’s DualArm Control System. Designed to simplify workcell integration, the DualArm System allows two robots and a positioner to be controlled in a single programme with co-ordinated motion and arc start synchronisation.
Production is over three shifts seven days per week and managed by one operator per shift, which corresponds to more than 200,000 arc starts in one month.
A touch screen monitor allows programmes to be selected, system status to be interrogated and order input to be made. The monitor connects to a Schneider web server allowing remote interrogation of system status and progress of production orders.
Plans are already in place for the future of the system.“We propose increasing the utilisation of the FANUC robot cell,” commented Mr Chevrier, Applications manager, Schneider. The system was designed with expansion in mind, by installing another work positioner on the other side of the robots [to the existing positioner] we will be able to utilise the system even further. The system will be able to comfortably weld high volume components on the existing side and lower volume, short runs, on the proposed side.
“Programming the robot is straight-forward using the standard FANUC Robotics welding specific software. Training is important and once the torch offset capability is understood and utilised only minimal skills are required to change locations and re-programme for new jobs.“
FANUC Robotics’ DualArm System allows two robots and a positioner to be controlled in a single program with coordinated motion and arc start synchronization. The system provides the optimum solution for dual robot processing on a single positioner.
The DualArm System includes hardware and software designed to simplify workcell integration. Setup time and process development are made easier through intelligent control of two Arc Mate series robots and positioners.The DualArm System provides metalworking manufacturers several key advantages:
- Provides a single point of control since both robots are controlled with a single teach pendant and CPU. This allows for easy operation, maintenance, programming and implementation.
- The use of two robots to weld parts is an ideal option for automotive components including axles, IP‘s and chassis.
- Helps expand the boundary for handling applications with heavy-duty payloads such as large automotive parts and truck frames.
- Controller cabinets provide space for extra I/O or auxiliary axis hardware.
- Increases safety by allowing operators to disable one robot to verify programs.