Advances in Welding Technology Minimize Error
Innovative welding processes empower your shop to do more with your existing workforce.
Posted: September 29, 2023
The continued increase in high-mix, low-volume applications in shops requires repeatable, accurate and high quality welds and other functions. Thanks to intuitive software, and cobots that require little to no programming, creating weld sequences is as straightforward as creating an online playlist.
First-of-its-Kind Robotic Port Welding System
Hydraulic cylinder fabricators are continually under pressure to quickly produce high-quality cylinders at competitive prices. To get higher throughput, repeatable quality, and less scrap in cylinder manufacturing, Acieta’s (Waukesha, WI) FastARC Port Welder (PW) robotic welding cell is the first-of-its-kind welding system that is purpose built for port welding on hydraulic cylinders, designed in collaboration with a cylinder manufacturer. The system features a FANUC 6-axis robot arm, unique multifunction end-of-arm tooling, and a Ferris wheel positioner for DMT parts load/unload. It is available with Miller, Lincoln or Fronius welding equipment.
With the FastARC PW, port welds are repeatable, high quality, and accurate during the entire shift. The FastARC PW has built-in parametric programming so operators just enter the cylinder specifications, and the system calculates the robot’s path. No additional programming or calculations are needed. This is especially helpful when changing from one part number to another or programming a new part number.
The Ferris wheel positioner allows operators to load parts while the robot is welding another cylinder on the other side. The robot works in a separate, protected space to keep people safe.
Users of the FastARC PW increase throughput by reducing weld cycle time, so they can make more cylinders in less time, which keeps production costs globally competitive. “Since implementing Acieta’s FastARC PW, we have seen a 90% increase in productivity and a 40% reduction in production time,” said Dan Van Eldik, CEO at Prince Manufacturing.
New Cobot Simplifies Automated Welding with App-based Software
ESAB Welding & Cutting Products (North Bethesda, MD) has introduced its first cobot for MIG and pulsed MIG welding applications on steel, stainless steel and aluminum alloys. Unlike the complex programming pendants of other cobots, the ESAB Cobot enables operators to teach welding paths using a software app that runs on a standard smart phone or tablet and a “Smart Puck” to hand guide the torch and record its position with the push of a button. Creating a weld sequence is as simple as creating a song playlist.
The ESAB Cobot features a Universal Robots UR10e industrial robot arm. UR is the automation industry’s leading provider of cobots and has an installed base of more than 50,000 cobots. Welding components include ESAB’s premiere heavy industrial welding system, the Aristo® 500ix pulse power source, the RobustFeed U82 wire feeder, an air- or water-cooled torch and accessories. A Siegmund 32”-x-48” welding table organizes components and enables moving the cobot around a shop.
Set up takes a few hours following step-by-step instructions accessed with a QR code. The cloud-connected ESAB software app offers free and fast in-app support from a team of experts that responds to inquiries in two minutes or less, as well as access to knowledge articles and extensive list of tutorials. The app automatically stores weld sequences, enabling them to be recalled even if they are deleted from a device.
Education Cart Streamlines Training
KUKA’s (Sterling Heights, MI) ready2_educate_arc education cart includes a KR AGILUS and Lincoln R450 welder. The all-in-one cart is mobile, fits through standard size doors, can be used without the welder for general training purposes, and can even be used for the manufacturing of smaller parts.
The cart also features a fume extractor, built-in fixture table and available options that include Touch Sense, Arc Sense, TRACC TCP and KUKA.Sim. KUKA also provides training courses and project-based digital lesson books with ready2_educate_arc. Developed as a complete starter package for schools, universities and company learning centers, the cart streamlines training and directly addresses current skilled labor shortages. The ready2_educate_arc was featured along with KUKA’s robots at FABTECH 2023.
VR Headset Designed to Inspire with Immersive Experience
Lincoln Electric’s (Cleveland, OH) Voyage™ Arc Virtual Reality Welding Headset is an interactive, immersive classroom platform that introduces students to welding fundamentals. The tool is designed to spark interest in careers involving welding by enabling tech-savvy students to learn in a virtual setting that many of them already enjoy in real life – an amusement park.
In addition, the Voyage Arc headset incorporates video gaming elements to keep the student motivated. As the learner masters each lesson, they are rewarded with “Spark” points they can use to customize their helmets. Learners are tasked with “welding” park equipment such as a roller coaster, Ferris wheel, sky drop ride or bumper car before earning a virtual ride.
Each student takes a self-guided tour through the amusement park by following narration and interactive instructions, stopping along the way to take 10 individual lessons, such as safety and PPE, common joints, and introductions to GMAW and SMAW. With visual cues and repetitive knowledge checks, students learn critical skills such as travel speed, position and contact tip to work distance. Students can save their progress and quickly pick up where they left off. The lessons can be individually selected and repeated as needed.
Fabricating Industry’s First Automated Fitting and Full-welding Machine
Voortman Steel Machinery (Monee, IL) has launched the revolutionary Voortman Fabricator, the premier welding system for structural steel. This new system is capable of producing the most common steel construction profiles – plates, angle irons, tubes, U-profiles, crane runway consoles – and is the world’s first welding robot that can both fit and weld. As a necessary solution to the shortage of welders, this robot allows for fully automated production of welding. Welders who perform this craftmanship can now focus on specialized welding projects instead. The welding process will no longer be interrupted, allowing for better planning and consistent quality.
Voortman Steel Machinery has also introduced DIGI-WELD, a software solution that fully automates the welding preparation process. This saves time with its analysis and correction of 3D models for welding information at just one click. The Fabricator is easy to integrate into any workshop and does not take up much space.
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