Sharpe

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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008

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Michael M. SharpeDirector - Engineering Materials Joining Segment

www.fanucrobotics.com



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Advanced Welding Technology 1

Advanced Welding Advanced Welding Technology 1Technology 1

Presented at:The Southern Alberta Institute of Technology

Welding Automation Forum

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How we used to do it?How we used to do it?

Heat and Beat: Highly skilled, but is this Intelligent Welding?Heat and Beat: Highly skilled, but is this Intelligent Welding?Video from Westinghouse archive footage

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Qualities of a skilled welderQualities of a skilled welder• Knowledge (Intuition?)

– Correct placement and sequence of the assembly to be joined

• Experience– Correct setting on the weld equipment

• Cautious– Approaches each weld with forethought – Controls quality and maintains equipment

• Accountable– “Automatically” re-works part– Tally’s the days work

• Productive– Always show up to work on time– Takes only scheduled breaks– Makes target production rates

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The latest in Intelligent Arc WeldingThe latest in Intelligent Arc Welding

A. New cutting edge robot designB. Advanced process controlC.Maximize your work cell productionD.Keep it running – uptimeE. Make it safe AND useableF. Sensing for guidance and quality controlG.Applications H.What’s next

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Contemporary Arc Welding dressContemporary Arc Welding dress--outout

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Design EvolutionDesign Evolution

Large J3interference

ARC Mate 100iB

External cable is not controlled

Standard Dress

Exposed cable

Limitation of J5 motion range

ARC Mate 100iB

Solution Arm Integrated Process Arm

ARC Mate 100iC

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Slim arm

ARC Mate ARC Mate iC Series Robots C Series Robots –– Universal Process RobotUniversal Process Robot

Integrated welding cable utilities

Dress-out

High motion performance

Larger motion area

Payload Up

Large area for wire feeder

iRVision Highest performance

arc welding robot

in this class

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Applications / Uses / BenefitsApplications / Uses / Benefits

Wheel weldingWheel welding

Increased arc densityIncreased arc density

ID welding ID welding

Arm to Arm Coordinated Motion

Arm to Arm Coordinated Motion

Improved accessibility Improved accessibility

EASY to Program with WeldPRO --- worry free with no cable to manage

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Compact Compact -- LR 200LR 200iiC/5L for arc weldingC/5L for arc welding

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Large area Large area -- MM--710710iiC/20L for arc weldingC/20L for arc welding

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Quick cable exchangeRemove torch flange holderRemove power pin and slide out torch cable

Wire liner exchangeRemove liner with front loading liner type or rear loading type liner

Torch body exchangeEasy exchange of the torch and consumables

Standard Torch and consumable offeringStandard Torch and consumable offering

Stan

dard

torc

hco

nsum

able

s

• Binzel– WH water cooled– ABIROB air cooled– ABROB water cooled

• Tregaskiss– Touch Gun air cooled– Continuous rotation of J6

Simple construction

1

3

Torch cable

Wire liner

Torch neck1

3

2

1

3

2

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Complete Welding packageComplete Welding package

ARC Mate 100ARC Mate 100iiC with AutoDrive 4R and i400 welderC with AutoDrive 4R and i400 welder

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NEWNEW Lincoln i400Lincoln i400

Integrated - Power Wave i400Separated - Power Wave i400

Integrated Op Box

R-30iA a-cabinet

Arc Link XT

PowerWave integratedPowerWave integrated

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Arc Welding Network controlArc Welding Network control

• Direct digital communication supports messaging and makes more sense than analog/digital conversion.

• Allows for a fully software configured automated welding system:

• Setup• Diagnostics• run-time welding information

over a common connection.

Digital Communications Performance

Process Selection through Process Selection through Teach PendantTeach Pendant

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•• Integrated Help and Integrated Help and DiagnosticsDiagnostics

•• HMI Development HMI Development EnvironmentEnvironment

•• Intranet/Internet AccessIntranet/Internet Access

•• Remote Monitoring/DisplayRemote Monitoring/Display

The latest Teach Pendant FeaturesThe latest Teach Pendant Features

PastPast:: Jog the robot and Jog the robot and teach positionsteach positionsPresentPresent:: Teach Teach Pendants have become Pendants have become a multia multi--purpose UIFpurpose UIF

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Integrated Help and DiagnosticsIntegrated Help and Diagnostics• Integrated Diagnostics

allows faster troubleshooting and improves uptime

When Error Occurs,

Simply Press DIAG key

Instantly get Diagnostic

Information for that Fault

• Increase your systems value by providing customized diagnostics• Custom System Alarms• Process or System

Specific Diagnostics• Easily created with

standard Web Tools!

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• Password Protect and Event logging: Prevents the accidental change of process parameters and logs changes through user access and hierarchy

• Production tracking: Monitors various robot process control functions and records the instance and number of occurrences

• Data Monitor Function: Monitor and log user selectable arc process variables and I/O including analog feedback for voltage and current

Quality ManagementQuality ManagementMAIN LINE 1

DETAIL Alarm G1 TOOL 15%PWD -027 Edit weld sch1 wire feedPWD -030 (250 to 275) IPM02 - APR - 98, 11:53:27NONE

Password Log5/10

1 PWD -003 Login (BOB) Setup2 PWD -002 Logout (JOE) Install3 PWD -021 Delete pos 1, PROG1.TP4 PWD -018 Write line 4, PROG1.TP

PWD -027 Edit Weld Sch 1 Wire fe6 PWD -001 Login (JOE) Install[ TYPE ] CLEAR HELP >

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Password Protect

Production Tracking

ProductionReport

Tag bad parts bad welds

+ =

Quality

Def

ects

0

10

20

30

40

50

60

70

80

90

100

P[4] P[5] P[6] P[7]

ADM, Quality of weld• Out of Range• Repair• Good

EXAMPLE:Part ID: XYZWeld ID: 1A-N44Weld ID: 2A-P36

How many parts produced

• Defect• Repair• Good

Prod

uctio

n Tr

acki

ng

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PC SimulationPC Simulation• PC based arc welding simulation

software• Cad data import and built in

model geometry• Aux axes and positioner support• CAD to Path teaching• All Arc Welding instructions• Teach Pendant connects to the

Virtual Robot in the PC package• Training Tool lowers training costs

and is portable• Familiar navigation of PC simulation• Runs just like the real robot

WeldPROWeldPRO

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• Arc Welding Applications– Replace touch sensing– Find joint offset on parts with an

identifiable pattern– Reduce tooling sensors (prox switches,

etc.)• Difficult applications now a reality

– Grating, expanded metal, corners, flanges and other.

– Parametric entry through recognition– Production recorder monitors the cell

operation and stores a series of snapshots when a fault occurs.

Integrated Vision for Arc weldingIntegrated Vision for Arc welding

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Pallet Welding applicationPallet Welding applicationChallenge

– Expanded metal and grating is difficult to robotically weld due to inconsistent trim edges

Problem– Low productivity– Over welding results

in poor quality and re-work

Solution– iRvision 2D vision to

locate the grating and offset the weld paths producing quality parts

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Intelligent Robot System for Loading of work cellIntelligent Robot System for Loading of work cell

• Contemporary– Fork truck Operator– Work cell Operator– Visual Inspection– Records good / bad parts– Dedicated tooling sensors

• Intelligent System (robot)– Fork truck Operator (or AGV)– Robot vision picks from bins– 3D Vision inspected parts– Networks information to PC– No additional sensors

Vision guided robot replaces operator

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Robot Vision for Weld Seam InspectionRobot Vision for Weld Seam Inspection

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MultiArm Arc / Handling System ExampleMultiArm Arc / Handling System Example

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Thank you Thank you



Sharpe

Business

advanced weldingtechnology