FANUC Automatic Welding Robot Workstation Turnkey Solution

I.Equipment technical specifications

1.1 The main purpose of the equipment is used to weld the bracket of the rollers and the bracket, etc.

1.2 Main technical parameters
Maximum welding workpiece: 3000x500x500mm
The  positioner payload: 500 kg

Workpiece Maximum rotating diameter: 1200mm

Welding positioner Repeat positioning accuracy: 0.5mm
Repeat positioning accuracy of the robot: 0.08mm

1.3 Equipment installation environment parameters
“Electricity: Three-phase AC 380V (15%), 50Hz (2%) Single-phase AC 220V (earth 10%), 50Hz (2%) Individual grounding protection wire: grounding resistance not greater than 4 ohms
Temperature: 5°C ~+45°C Relative Humidity: <90% Surrounding Environment: Ventilated, away from vibration sources.
Gas supply: Carbon dioxide gas

According to the site conditions, gas cylinders can be used to supply gas in parallel, or liquid gas tanks and pipelines can be used to supply gas, the purity of carbon dioxide gas is required to be 99.5% or more, and the gas supply pressure is 1.2~1.6MPa.
-Foundation Requirements.
Concrete strength:210 kg/cm(3000 1b/in).
Foundation unevenness: <3mm Thickness: 150mm

II.Equipment Performance

The robot welding workstation consists of a robot mounting base, fully digitalized welding power supply, wire feeding system, water-cooled welding torch, clearing torch and wire cutting mechanism, and positioner. Robot mounting base and other steel charcoal assembly structure, with a good stiffness/weight ratio, while having the use, maintenance, and commissioning convenience, the overall layout of the machine is reasonable and beautiful. The air circuit, control, robot hand alarms and other parts of the center are imported brand-name products, with reliable performance. The whole machine is characterized by high reliability and low energy consumption. Equipment processing precision, advanced control system, reliable, durable, can be continuously cut 24 hours/day, with each heavy-duty work capacity. All parts of the machine tool are sealed and protected reliably without leakage, the lines and pipes are reasonably configured, beautiful, and clearly labeled for easy installation, use, and maintenance, with good electromagnetic compatibility and snow resistance. The design of the mechanism is in line with the principle of ergonomics, and it is easy to operate.

2.1 Robot controller (FANUC)

The R-30iA Mate robot control cabinet is controlled by an intelligent motion control system based on FFAUNC’s industrial computer technology. The full-digital homologation module provides drive power to the AC homologation motors of the robot’s 6 joints and has the ability to extend the control of 24 external homologation motors.
Power supply for the robot’s six joints AC servo motors, the ability to extend the control of 24 external servo motors axis synchronization coordinated control, complete linear interpolation, and arc interpolation. A friendly and simple programming interface with icon-based buttons makes it easier for operators to learn and more comfortable. Distributed hardware structure and streamlined instruction set software can ensure strict timing and task execution. External/0 points can be expanded at will. The open structure allows connection to networks such as Ethernet and Device-net. In addition, the self-circulating ventilation system with filters ensures normal operation in the range of C-45%C. The robot system is equipped with a programmer with a large screen color work CD display, which is easy to operate and program, and has the functions of online welding parameter modification and self-diagnostic fault display. Convertible Chinese/English display for operator’s convenience and equipped with a dead-man switch to further ensure safety.
Welding software is embedded in the control system.

 

 

• 2.2 Lincoln Welding Power Source
  The Power WaveR350 is a compact and versatile robotic welding power source.
  With built-in wire feeder control, it is designed specifically for robotic welding applications. It enables very fast arc response, includes 65 standard welding optimized process parameter settings, and can efficiently convert input power to reduce shipping all in a compact and sturdy housing. Operating Costs
  Key Features.
• Built-in Wire Feeder Control – Standard internal control for thousands of compatible wire feeders, allowing users to modify settings on the robot’s teach pendant.
• PowerConnectTM Energy Connection Technology (patent pending) – Automatically regulates the input power source to maintain constant welding output over the entire input voltage range.
• TribridTM Energy Module – High power factor and efficiency for superior welding performance.
• Production Monitoring 2.1 Production monitoring tracks equipment usage, weld data storage, and configures fault limits for production analysis and process improvement
• Assisted Power Surge Blocker technology (patent pending) for simultaneous use of grinders and other machines requiring high start-up currents (60 amps or higher) on the standard 115-volt (10-amp) auxiliary power outlet. Welding performance is unaffected when using grinders and other equipment requiring high start-up currents (60 A or higher inrush current) simultaneously on the standard 115 V (10 A) auxiliary power outlet.
• Compact and robust housing – IP23 to withstand harsh environments
• Standard Ethernet -Easy software upgrades via powerwavesoftware.com.

 

2.3 Wire feeder

The AutoDrive TM! 4R90 solution represents Lincoln Electric’s best technology and welding process, integrating a high-efficiency inverter power supply designed for high-end robotic welding and a compact, durable wire feeder
advantage:
·Integrated design – the design is “nested” on the upper wall of the FANUC robot.
·Durable —- The patented MAXTRAC wire drive is precision cast aluminum designed to provide reliable feed force.
·Easy to use —- Unlike other competing models, no tools are required for the drive wheel, wire feed guide, or pressure arm adjustments.
“High Performance – Copper torch connections provide more reliable electrical connectivity and more efficient energy transfer.
Very good torque —- Fast acceleration reliably pulls the welding wire from the guide wire tube.
·Precise Control —- Dual spring pressure alarms provide clear adjustments to optimize the pressure for different coal wire types.
·Welding effect —- The high-resolution tachometer controls the wire feeding speed precisely.
Optimized robot solution – compact, lightweight packaging maximizes robot acceleration performance and processing power. Design features:
-The design of 4 driving wheels makes the wire feeding performance excellent
·Double elastic pressure wall design brings precise control
·Quick self-locking wire godet (without tools)
·The wire guide plate supports the whole wire feeding path
The design of the wire feeder is “nested” in the upper alarm of the FANUC robot ARC Mate 100iC
“Optimized size and weight – 13.5lbs (6.1kg) – LxWxH inches (mm) 9.1x 7.5x 8.4(231x 191x 213)

Reliable and durable design – High-resolution quadrature tachometer for further control of wire feed speed – High-efficiency engine for long service life Welding specifications

2.4 Water-cooled torch
Equipped with a new generation of robot water-cooled welding torch systems, it can meet all the requirements of robot welding. The welding torch has a compact structure and a large rated current. It is a very good choice in terms of convenience of use and welding effect. Due to the modular design, the goose collar and cable assembly can be quickly replaced while maintaining the TCP (tool middle point) parts. Robust torch design with optimized TCP repeatability for continuous precision
welding