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Automation and Robotics

ZSB, MAN, mobile robotic stations Starachowice

 

Client: MAN
Location: Poland, Starachowice

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The problem: The client's expectations were to increase the number of components produced and, at the same time, to achieve greater replicability in their welding. An additional requirement was that the solution provided should be mobile enough to make it possible to move it as a whole to another location on site if necessary.

The solution

 

APA GROUP engineers designed and delivered a comprehensive solution in the form of two robotic welding cells together with a dozen or so welding devices, for which a magazine was also designed and delivered.

 

 

 

The project consisted in designing and providing the client with a solution that would allow the automation of welding of small components, which are then used as subassemblies in mass production of buses.

 

Two identical independent welding cells were built within the project. Each cell consists of a welding robot, moving on a linear unit and an external 3-axis H-type rotor, fully synchronized with the robot. This allows the welding process to run continuously even on the most demanding seams.

 

To ensure stability and replicability of the welding process, the stations are equipped with an automatic control system and correction system of the tool center point (TCP) of the robot. In that, the risk of welding quality loss in case of unwanted and uncontrolled change of the robot's TCP was reduced. Such a loss may occur, for example, as a result of thermal distortion of the welding torch, which is a natural phenomenon in the welding process.

 

As part of the project, APA has also designed and manufactured a dozen welding devices that can be used interchangeably at both stations. Robotized stations are equipped with RFID system. Stationary read heads were placed on the rotors, and each device was equipped with a data carrier, so that the system automatically recognizes which device the rotor at the station was armed with. The tool magazine has been designed and built between the two cells to make the logistics as easy as possible and to shorten the time needed to replace the device at the station.

 

The 'mobility' of the station required by the client has been ensured by placing the entire cell on independent steel segments. These segments are interconnected, but if it is necessary to move the station to another location, this solution allows each of them to be transported separately. The station has also been equipped with stationary extraction of welding dusts and fumes, which enables the capture and removal of harmful fumes.

 

The entire station has been integrated with the necessary safety systems, which guarantees complete safety for the operator.

 

 

 

Benefits

 

  • increased number of parts produced
  • greater replicability of welded parts
  • operator safety
  • no need to be in a harmful environment

 

 

 

 

Technologies used

 

 

  • Siemens 319F-3 PN/DP central unit
  • SIMATIC PC677 operator panel
  • TIA Visualisation Portal
  • Profinet network (ProfiSafe)
  • Hollow Wrist KUKA Robot
  • KRC4 robot controller
  • Linear unit KL 1000-2
  • BART welding fume and dust extraction
  • H-type rotor
  • RFID system
  • Safety Systems (EUCHNER, SICK, SafeOperation)
  • FRONIUS welding power source
  • 'Cold' CMT welding process

 

 

 

 

 

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