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Tilbox shortens route from order to welding robot

The Valkenswaard-based supplier of upper and lower toolboxes for trucks and trailers is investing in further automation of its production process. As a next step, Tilbox has implemented a Valk Welding robot with an automatic programming system, significantly shortening the workflow from work preparation to welding robot. “Within 30 seconds, we have a welding program ready for a box. The extra capacity has allowed us to shorten delivery times on this line. This way, we produce more intelligently and serve the market better,” says Dion van Dommelen, the system engineer responsible for the renewal process.

Trucks and trailers are often equipped with a toolbox to safely store tools. “Although bodybuilders can make a box themselves, they still order from us because we can do it faster and cheaper due to our specialisation. However, orders are often placed only when a customer knows how much space is left. Delivery time therefore plays an important role. It often involves single pieces or small quantities. In addition to customisation, there is usually a high degree of standardisation, with mainly width, height, and depth varying.”

With the welding robot or manually?

“We already weld standard boxes on a welding robot based on a number of fixed programs. In the case of a different size, adjusting the welding program takes so much time that the decision to weld manually was quickly made. We wanted a way to quickly create welding programs. The question was which player in the market could help us with this. Valk Welding had experience with this and could show, based on previously realised projects, how you can adjust existing programming blocks within QPC with macros, so you don’t have to reprogram every recurring operation,” continues Dion.

Quick Programming Configurator (QPC)

QPC is Valk Welding’s own software development, specifically designed to simplify and even automate the programming of the welding robot within product families. As soon as a customer places an order via Tilsmart, the information is known, and the program can be generated using QPC software. Repetitive operations are recorded in macros from the main program. By reading the macros into the DTPS programming system for Panasonic welding robots, a program for the welding robot is often ready within half a minute. This results in significant time savings in work preparation. Tilbox has developed an online tool that allows customers to configure their box. Once the order is placed, the data is sent to the robot. Using the QPC software, a program can be quickly generated, and the order can be produced.

TRACK-FRAME-E with 2 clamping stations

The system installed by Valk Welding consists of a Panasonic welding robot on a track that serves 2 clamping stations, each with a manipulator. The manipulator is suitable for certain types of boxes that fall within a specific range. About 90% of these types of boxes fall within the range, with a few exceptions being welded as before.

Responding to further growth

“We want to continue growing by optimally supporting our customers with our service and products. Our online ordering tool not only provides extensive information but also makes the ordering process simpler and more efficient. Moreover, the investment in our new welding robot system ensures that we remain flexible and ready to realise the increasing production capacity,” concludes director Gertjan Grimbergen.

www.tilbox.nl

Within 30 seconds, we have a welding program ready for a box.

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