Escolar Documentos
Profissional Documentos
Cultura Documentos
Table of Contents
Construction Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Building Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Agricultural Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Construction Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Petroleum Extraction Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Metal Fabrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil and Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Metals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CONSTRUCTION VEHICLES
Arc Welding
CHALLENGES
Provide flexible robotic welding system
to automate welding of new design of
motor grader with seven models. Front,
middle and rear assemblies are manually
pre-tacked prior to robotic welding, then
manually welded together to form the
final frame.
Large, heavy parts consist of mild steel
plate 19-76 mm thick. Depending on the
model, rear frames weigh more than
2,000 kg each; front frames weigh
approximately 1,450 kg and mid-section
frames weigh approximately 1,500 kg.
Each frame section requires 50-150 welds,
which range from 102-2,743 mm L.
Improve productivity and shorten lead time.
Reduce dependency on skilled human
welders due to shortage.
Make aesthetically pleasing welds on
outside of grader frame that do not need
to be ground down prior to being painted.
Accommodate low ceiling in plant with
non-gantry robot system.
SOLUTION
Yaskawa Motoman provided a custom
welding system, including:
Motoman 20-kg payload, extended reach
robot with controller and base riser.
5-m servo track with 1,000-kg capacity.
(2) Tandem-arc GMAW torch packages,
and 500-Amp digital welding power
sources, with interface to robot controller.
1,000-lb bulk wire reels with high-speed
wire-assist feeders.
Automatic wire cutter and tandem torch
reamer.
200-V Com-Arc seam-tracking and touchsensing package.
Motoman two-axis servo-tilt/rotate
skyhook
positioner with 3,000 kg payload capacity.
X-axis orbital speed is 0-1.9 rpm. Y-axis
orbital speed is 0-2.7 rpm.
Motoman three-axis, two-station servopowered positioner. Includes two
headstock/tailstock positioners mounted
on a rotating base axis. Each headstock/
tailstock has a 3,000 kg payload (6,000 kg
FIXTURES/TOOLING
Customer provided manual fixtures for
this project. Operators manually bolt frame
parts onto the two positioners. Robot
welds grader front and rear assemblies on
the headstock/tailstock positioner; midsections on the skyhook positoner.
PROJECT RESULTS
Robot system meets or exceeds all project
goals. Allows customer to build on two
shifts what would have taken three shifts,
eliminating a production bottleneck.
motoman.com
ACS-082-B
BUILDING COMPONENTS
Arc Welding
CHALLENGES
Robotically weld large assembly and
fabrication tables that are 4-m L x 2-m W
and weigh approximately 2,450 kg, as well
as subassemblies that weigh 181-227 kg
each. Tables are mild steel 6-13 mm thick
and each requires 660 single-pass welds,
ranging from 25-152 mm long.
Improve safety and reduce high turnover
due to manual welding in 100-degree plus
heat during summertime.
Provide flexible welding system that can
accommodate a wide variety of models
and subassemblies, and has capability to
perform 85% of welding on large tables.
SOLUTION
Yaskawa Motoman provided two
MotoSweep cells, each including:
Six-axis Motoman Expert Arc robot
with controller.
MotoSweep transport beam. Robot is
invert-mounted from MotoSweep
transport beam and controlled as an
external axis.
FIXTURES/TOOLING
Customer provided their own fixtures. Each
MotoSweep cell has two stationary holding
fixture tables, one per side. The robot can
process the same type of parts on both
sides or different parts can be run on
opposite sides of the same robot cell. Parts
are fixtured very tightly and concisely to
ensure welded parts
are square and flat.
PROJECT RESULTS
Highly flexible, extended-reach robot
system meets or exceeds all project goals
and objectives.
Conservatively speaking, robot system
payback was less than six months.
Production capacity increased from 2025 per month to 6-7 per day, enabling
customer to bring out-sourced production
of 40 units per month back in-house.
motoman.com
ACS-083-B
AGRICULTURAL EQUIPMENT
CHALLENGES
Provide flexible system to weld and handle
12 different hay baler roll assemblies.
These consist of tubes with trunnions on
each end that are tack-welded in place,
plug-welded and then final-welded.
Tubes are 1,170-1,556 mm L and have ODs
ranging from approximately 89-168 mm.
Final welded assemblies are 1,318-1,959 mm L.
System must be designed to hold enough
parts to support approximately one hour
of unattended production.
Improve weld quality and reduce rework.
Achieve run-out tolerance within 1.5 mm
for tubes and 0.4 mm for trunnions.
Achieve cycle time of approximately
5-6 minutes per part.
SOLUTION
A Yaskawa Motoman custom welding and
handling solution, including:
Two Motoman robots with base risers.
The arc welding robot features a 50-kg
payload; the material handling robot
features a 200-kg payload.
FIXTURES/TOOLING
Yaskawa Motoman provided a custom
pneumatic multi-function mechanical
gripper for the material handling robot
that handles two trunnions and one tube/
roll assembly of the required sizes. Gripper
includes open/closed sensors, and laser
sensor that searches for slots or holes
in tubes and verifies length/diameter.
Customer-provided pneumatically clamped
mechanical slide welding fixture is mounted
on heavy-duty positioner.
PROJECT RESULTS
System exceeds requirements for quality
improvement. Run-out tolerances are
consistently held to 0.2 mm on trunnions
and 0.75 mm on tubes, which is twice as
good as the goal of 0.4 mm on trunnions
and 1.5 mm on tubes.
motoman.com
ACS-099-B
CONSTRUCTION EQUIPMENT
Arc Welding
CHALLENGES
Provide flexible robotic system capable
of welding 26 different outrigger beam
models distributed across three part
families. Mild steel parts range from
approximately 1,524-3,658 mm L,
6-19 mm thick and weigh 227-771 kg.
Each beam requires 7-10 welds, ranging
from approximately 51-3,048 mm L.
Achieve 27-minute cycle time for all
models (one part every 0.45 hours).
Depending on model, beams take
3-4 hours to weld manually.
Increase throughput and productivity to
enable out-sourced beams to be brought
back in-house.
Improve weld quality and consistency.
Allow skilled manual welders to be
redeployed to other jobs within the plant.
SOLUTION
Yaskawa Motoman provided a flexible triple
welding system, including:
(3) 20-kg payload robots with individual
controllers and base risers.
(3) Fronius TimeTwin TPS 5000 digital
weld packages.
FIXTURES/TOOLING
Yaskawa Motoman provided hydraulic
clamping fixtures for the two headstock/
tailstock positioners. A large spanner
between the HS/TS faceplates is adjustable
to accommodate various beam lengths.
Two alignment clamps and two swing arms
per fixture hold each part for welding.
Fixtures include part-present and clamp
open/closed sensors.
PROJECT RESULTS
Motoman system welds parts significantly
faster than the 27-minute cycle time
requirement. Some parts are welded in
13 minutes. Most parts average
17-18 minutes.
motoman.com
ACS-110-B
CONSTRUCTION EQUIPMENT
Arc Welding
OVERVIEW
After experiencing an increase in the
number of orders for its hydraulic
excavators, a global construction
equipment manufacturer suddenly found
the manual welding process at its new
assembly plant to be insufficient to meet
demand. The manual welding stations
were responsible for the final welding of
cab bodies for eight different models of
hydraulic excavators. With the sheer size
of the three large cab body components,
and a combined weight of 12,000 pounds,
each station would require its own costly
positioning device in addition to welding
equipment. The work also meant dealing
with quite a bit of tolerance (part variation),
and required the welder to compensate for
gap sizes from 0-6 mm. Since the finished
weld would be highly visible after the
excavator was fully assembled, presenting
a consistently perfect weld was absolutely
necessary.
CHALLENGES
Position large and heavy components
quickly and efficiently
Produce consistent welds for eight
different models that meet stringent
inspection requirements
Adapt welding parameters for varying
tolerances in gap sizes up to 6 mm wide
SOLUTION
Yaskawa Motoman provided two dual
robot dual positioning cells designed to
handle weights up to 15,000 pounds. The
positioners had two axis of rotation in
addition to Z-lift capacity.
PROJECT RESULTS
After passing a macro etch test to verify
the internal quality of the welds, as
well as a visual test for consistency, the
manufacturer installed the robotic welding
system at its new assembly plant.
motoman.com
ACS-134
Arc Welding
OVERVIEW
Following a spike in orders due to growing
demand for oil and gas refining products,
a global supplier of petroleum extraction
equipment identified the need to improve
manufacturing efficiency. Specifically, the
company sought to increase productivity
in the manufacturing of walking beams
and frame bases, essential components in
its pump jack artificial lift systems that are
used to extract crude oil from the ground.
While the design of pump jack systems
hasnt changed significantly in 60 years, the
company realized it needed to change how
it manufactures walking beams and frame
bases in order to remain competitive and
control costs. Thats because, while the
frame bases are a single, standard size, the
manufacturer produces walking beams in
ten different sizes. The companys maximum
walking beam size is 40" x 14" x 310" with a
maximum weight of 6,740 lbs.
It was determined that utilizing an
automated robotic welding solution in the
production of walking beams and frame
bases was key to achieving the necessary
CHALLENGES
Increase throughput by 65 percent,
compared to previous production operations
Improve weld quality
Accommodate ten different sizes of
walking beams
SOLUTION
FRAME BASE
WALKING BEAMS
PROJECT RESULTS
Following a customer run-off to verify the
effectiveness, quality and efficiency of the
walking beam and base frame welding
solutions, the manufacturer took delivery
and began its welding operations.
motoman.com
ACS-131
METAL FABRICATION
Arc Welding
OVERVIEW
A full service metal fabrication shop and
contract manufacturer improved weld
quality, throughput and lead times by
installing Kinetiq Teaching on a robotic
welding system. An early adopter of robot
technology for spot welding and plasma
cutting, the company utilizes eight robot
welding systems.
The company offers services from design
to complete manufacturing, specializing in
finished in-the-box products. Clients include
firms in office furniture, transportation,
material handling, display systems,
consumer products, industrial machines,
medical equipment, electronics, military,
automotive and aerospace sectors.
CHALLENGES
SOLUTION
PROJECT RESULTS
The companys president saw the potential
of Kinetiq Teaching while attending a
trade show and installed it on an existing
Motoman robot. This eliminated the need
for a large investment in training for manual
welders to become robot programmers.
By utilizing Kinetiq Teaching, manual
welders can program and make fixture
motoman.com
ACS-132
Arc Welding
OVERVIEW
CHALLENGES
SOLUTION
Yaskawa Motoman provided a triplerobot welding cell coordinated by a
single controller (triple robot control).
The cell consists of two Motoman
MA1900 welding robots and one Motoman
HP600D material handling robot. Multiple
robot control allows the robots to work
together on the same task or perform
independent tasks with each arm.
PROJECT RESULTS
As the manufacturer required, production
of manifold headers now takes place in
three shifts, around-the-clock, including
times when workers arent present.
Accufast and ComArc sensing technology
reduce cycle times while ensuring accurate
weld placement on all manifold models to
provide leak-proof, high-quality welds.
motoman.com
ACS-133
TRANSPORTATION
Arc Welding
OVERVIEW
CHALLENGES
SOLUTION
Yaskawa Motoman designed four robot
welding cells with one extended-reach
Motoman MA3100 arc welding robot and
one Motoman MH50-20 material handling
robot per cell; both robots in each cell are
controlled by a single Motoman DX100
controller. Multiple robot control allows
both robots to work together on the same
task or perform independent tasks with
each arm.
PROJECT RESULTS
The robotic arc welding systems reduced
cycle time and increased efficiency while
maintaining the high standard of weld
quality required.
AccuFast, ComArc and Multi-Layer
software ensure accurate, high weld quality
for contoured parts, long seams and
part variations.
motoman.com
ACS-135
METALS
Arc Welding
OVERVIEW
A bridge component manufacturer was
seeking a quicker and more efficient way
to manufacture its steel cross frames. The
cross frames are built to be bolted inbetween the steel girders that run parallel
to the flow of traffic, adding structural
integrity and support to the bridge. The
manufacturers welding process for the
cross frames was all manual. With part
dimensions of 8 feet by 12 feet and weights
up to 2,000 pounds, welders had to spend
a significant amount of time using an
overhead crane to position the part from
one weld to the next.
The manufacturer had previously
considered automating its cross frame
welding process. But with the twodimensional standard in drafting bridge
designs, most robotic welding systems
required an engineer to complete the
expensive and lengthy process of converting
the designs into a three-dimensional format
before the information could be added
into the robotic welding program.
SOLUTION
Additionally, any robotic welding system
would have to compensate for the tiny
variations in size from one cross frame
to the next where the bridge bends and
pitches. Yaskawa Motoman was the only
robotic automation company able to
address these two issues.
CHALLENGES
Develop an interface capable of accepting
information in two-dimensional format
Produce consistent welds among series of
cross frames with varying sizes
Accurately position and weld large
steel components with weights up to
2,000 pounds
Decrease process time to allow
manufacturer to be more competitive
PROJECT RESULTS
After installing the equipment, a part
runoff was completed to verify effective
operation. Yaskawa Motoman provided
on and off-site training, and continual
technical support to ensure success.
motoman.com
ACS-136
motoman.com