New welding cell for quality, repeatability and enhanced production

New welding cell for quality, repeatability and enhanced production

Keywords Welding,Robotics

Modular Welding Ltd has recently supplied a twin table robotic welding cell to WST Engineering of Solihull. The cell is part of a turnkey manufacturing system for an internationally renowned automotive company. This has ensured production targets, reduced defects, and maintained the excellent appearance and consistent quality of the company's automotive products (see Plate 3). The system manufactures a complete Advanced Gas Recirculatory tube which returns the exhaust gases to the engine for increased fuel efficiency, improved performance and power output, and a reduction in harmful products such as carbon particulates. The automatic robot welding cell achieves a minimum distortion to provide an airtight seal against loss of these automotive exhaust gases by combining a process that promotes very low heat input to prevent the flange distorting. WST has worked with automotive designers to improve the product both from engineering constraints and cost down considerations.

 Plate 3 Modular Welding of Birmingham uses the latest techniques to maintain quality and appearance of welded joints

The turnkey system includes automatic tube manipulation, trimming, hole punching, de-greasing, welding and final vacuum test. The welding cell was conceived, manufactured and installed exclusively by Modular Welding Ltd.

The robotic welding cell MIG welds two flanges onto the formed tube. Both the flanges and tube are made from Stainless Steel type 304L. The cell incorporates a single six-axis Panasonic Robot interfaced with an advanced synergic welding power source.

This unique welding power source achieves extremely low levels of splatter,which is vital for subsequent assembly operations. It is also programmed to use just under 100 Amps at 19 Volts with a 1.2mm MIG 308L wire; a combination that ensures very low heat input and stable Arc conditions with uniform droplet transfer resulting in minimum distortion of the flange.

A single operator assembles and loads the three components into the specially designed tooling. The components are then clamped automatically before welding begins. The cell achieves a cycle time for the welding operation of just 20 seconds per component.

WST has achieved all the objectives set by the customer both on cost down,performance and production capability of the product.

All enquiries to: William Bourn, Modular Automation Ltd, Talbot Way, Small Heath Business Park, Birmingham, B10 0HS. Tel: +44 (0)121 766 7979; Fax: +44(0)121 766 6385.