New cells installed for robotic welding of vehicle components

New cells installed for robotic welding of vehicle components

Keywords: Robots, Welding, Automotive

Two robotic welding cells have been supplied by Motoman to the Birmingham factory of Lander Automotive to automate the manufacture of complex assemblies for the new Jaguar X-type saloon car. Anticipated production volume at Halewood is in excess of 130,000 per year.

The larger of the cells is based on two Motoman UP-series six-axis robots and two auto indexing workstations, each of which has a horizontal, 250kg capacity manipulator. It is a standard configuration called "Arc System 6000"which has been customised with the addition of light guards and a PLC to Lander specifications for part sensing and controlling the pneumatic clamping. The cell carries out 49 MIG welds on the tubular rear seat frame for the X-type (Plate 1).

The second cell, called "Arc System Batchweld", is based on a single Motoman UP-series six-axis robot with a manually indexed turntable having 100kg capacity per station. A total of 12 arc welds are completed automatically on an X-type radiator support cross member and other components.

PWO near Strasbourg, Lander's trading partner in Germany, is also a user of Motoman robotic welding systems and recommended them to the Birmingham company. The electrically actuated robots are built by Yaskawa, Japan, and feature a large working envelope and a flexible conduit which routes all services from the base upwards, eliminating trailing hoses and cables.

 Plate 1 A rear seat frame for the X-type is fixed at the second station of the Motoman twin robot cell while the previous frame is being welded

Lander, a first and second tier automotive supplier, is on record as being very pleased with the short delivery time for the Motoman cells as well as the supplier's general response to the project. It was also impressed with the group's Swedish headquarters where final buy-off took place. The Motoman training in Banbury was easy for semi-skilled operators to follow, and although the supplier wrote the original programmes, the course enables easy program modification by Lander staff using the teach pendant.

There have been few problems with the new robotic welding cells since they were installed. In particular, ignition failures are minimal, mainly due to the first class interface between the robot supplier's XRC controllers and the Kemmpi weld sets.

For further information contact: John D'Angelillo, Managing Director, Motoman Robotics (UK) Ltd, Unit 2, Johnson Park, Wildmere Road, Wildmere Industrial Estate, Banbury, Oxfordshire 0X16 3JU, UK. Tel: 01295 272755; Fax: 01295 267127;E-mail: johnd'angelillo@motoman.co.uk;Web site: www.motoman.se