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TASK
Robotic automatic welding is a proven way to improve quality while reducing cycle time. Vast working envelopes can be covered when robots are coupled with gantry systems to tackle the largest parts were long welds abound. The best performance is accomplished while welding 'in position', namely using the torch pointing down in order to take advantage of gravity. When parts are large and heavy, this task becomes challenging.
SOLUTION
GÜDEL designed a custom module to include two rotary axes, mechanically designed to sustain the cantilever loads. A flexible counterweight allows to balance the system when significant variations in parts weight and center of gravity location occur.
SCOPE OF SUPPLY
A combination of geared slew bearing coupled to a AE120 gearbox provide the heart of the support and drive. This layout accomplishes very smooth and accurate positioning while sustaining significant dynamic forces. External servo motors linked to the kinematic model of the welding gantry allow to synchronize simultaneously 12 servo axes providing a smooth three dimensional path. The resulting 'dance' performed is a mathematical marvel!
RESULT
This solution provides complete part manipulation to allow optimal orientation in automatic welding processing. The part shown in the pictures used to be processed in 30 hours of manual welding. After the implementation of this system, test show a processing time of 2.5 hours with a significant improvement in weld quality.
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