Smart Industry Robot Solutions

The development of software-based solutions and applications of intelligent laser sensors made it even possible to use welding robots for batch size 1. This means that ‘single piece flow production’ and ‘mass customizing’ are possible. Behind the scenes Valk Welding is working on even more ‘Smart Industry Robot Solutions’.

The offline programming system DTPS has been the start in the nineties for a flexible deployment of Valk Welding Welding robots and the development of new software modules to further shorten the programming process. The development of APG (Automatic Path Generator) has been initiated as the next step in ‘Smart Robot Industry Solutions’.

Based on 3D CAD files and data from ERP the APG software automatically generates programs for the welding robot which next to the positioning of the welding torch, also contains the torch angle, and the right parameters such as voltage, weaving parameters, crater filling parameters, etc. Unique is that the user can integrate it into his own welding strategy.

Companies like Van Hool (truck and bus construction), Auping (beds), Thyssenkrupp Encasa (stairs) and Profielnorm (mezzanines) have thus the entire programming process for the welding robots automated and thereby realized a one piece flow production. Adriaan Broere: “Mass customization with batch size 1 on the welding robot is made possible”.

One of the achievements of the deployment of APG in the production of customized products, is that companies have been able to switch to an order-driven production and can further shorten their delivery times. "

Meanwhile behind the scenes Valk Welding works intensively on further ‘Smart Industry Robot Solutions’ to make further flexibility of the welding automation possible.

• Automatic program selection with the use of barcodes and RF-ID’s.
• Automatic selection of the jig by a handling robot and the use of AGV’s, which is an integrated part of the logistics chain in the production.
• Robots give more and more real-time feedback via Ethernet interfaces, so that we are able to capture the programmed paths as well as the actual travelled paths including the associated welding parameters. This provides new opportunities to monitor the weld quality and quickly intervene if something goes otherwise than planned, even with a very small production volume. (Normally, you had a larger series with lots of opportunities to adjust things by simply repeating the same trick but this is impossible if you produce a small series or even a single piece.)
• Seam tracking systems with laser sensors, such as the Arc-Eye from Valk Welding makes welding robots smarter and can absorb more defects, which guarantees a higher weld quality.
• Increasing in service diagnostics, allowing welding robots to be preventively serviced in time, or allowing the logistics department to receive a signal that there is almost a new wire drum required. The robot itself can also do a service request via email, SMS, etc.

Terms and conditions for unmanned programming is that programs can be acquired directly by the robot 1: 1 and do not need to be corrected. Adriaan Broere: ‘Our calibrated welding robot systems together with the Seam tracking systems are excellent for that’.