Welding robots 2.0
Van Lierop already had 2 Valk Welding systems with Panasonic VR-008 welding robots on an H-frame setup, each with 2 work stations. Van Lierop: "This makes it possible for us to completely weld smaller work pieces in one set-up. For larger assemblies consisting of several sides we first made the separate assemblies in series and then put them together entirely manually. That involves a lot of handling and calls for extra internal storage. Together with Valk Welding we analysed how we could get rid of those steps. The result was a setup with 3 work stations next to each other that were operated by a Panasonic TA-1900 welding robot suspended on a gantry on a track with 13 m stroke. Parts which are welded on the outer stations and then assembled on the middle station are completely welded by the robot. That made it possible to eliminate a number of internal steps and we are now able to produce even more profitably in larger series and with less manual work.
Installation universally deployable
The welding robot installation has three 4 x 2.5 m work stations but can also be converted into two stations with a work range of 6 x 2.5 m by replacing fencing and moving counter bearings. The welding robot installation is currently being used to produce an order of 4,000 cheese boxes, but in December we will be using it for other, larger work pieces that are assembled in multiple steps. We're now making preparations for that: good preparation is often half of the work!
Win-win situation
Van Lierop believes that this way of working creates a win-win situation for the employees, the company and the customer. "The welding work has now become less mono-tone. Employees aren't challenged by the forecast to weld 4,000 pieces, but yes they are by the prospect of helping out with the setting of the welding robot. Their knowledge of the welding sequence, heat input, tolerances and product specifications are of great importance here. And the benefits yielded by automation will also help us to keep the work within the Netherlands. That would no longer have been financially possible with manual welding."
Ready for the next step
To Van Lierop the investment in the welding robot installation was therefore a big step in the right direction: "The welding robot is programmed offline. We can weld larger products with internal steps in both steel and stainless steel and retool faster with tools that we have developed ourselves. But the hectic market continues to demand further measures. We will have to respond more to the 24/7 economy and take a closer look at the limits of automation. Unmanned welding could be the next step, concludes Hans van Lierop.
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