Weld any batch size with the robot

Many production processes are automated using industrial robots. They move and control tools with the robot controller turning code into programmed procedures. For large-scale production, such as in the automotive industry, the procedures are programmed once for their respective purpose when the robot is set up and do not change during the production phase. In view of the trend towards many variations and small batch quantities, the time spent on programming is becoming increasingly important for the efficiency of processes. At least when the robot is being taught and consequently is not being used productively during the programming time. Offline programming away from the production area offers an alternative solution here and as a result production does not need to be interrupted for programming. This improves the productivity of robots and the use of welding robots no longer needs to be limited to large-scale production.

Programming and simulation software

In 1996, Valk Welding of Ablasserdam, Holland, which specialises in the automation of welding processes, launched with DTPS (DeskTop Programming and Simulation System) a software system onto the market which for the first time allowed welding programmes to be created on a separate computer. The fact that it used Panasonic software, with identical programming on both the computer and the robot, was unique. It was now possible to prepare the programme without interrupting welding production, and as a result increase significantly the run time of the welding robots.

Valk Welding has, in close collaboration with the software specialists of Panasonic Welding Systems in Japan, further optimised the software. At the heart of the development were the needs and suggestions expressed by the users of Valk Welding systems to the Dutch system integrator. With the latest generation DTPS G2, any workpiece can be programmed and presented complete with template and the whole welding robot in 3D with solids. All of the functions of the Panasonic arc welding robot are integrated into the software.

Use for small-scale serial production

During the last five years a lot has been invested in specific software solutions to allow medium-scale, small-scale and piece production with the welding robots. Valk Welding has therefore played a part in the market trend of offering more product variations in small quantities. DTPS and the possibility of parametric programming played a crucial role here.

No need to make adjustments directly on the welding robots

In order to enable the automatic flow of programming for variants within a product family, Valk Welding also develops Custom Made Robot Software (CMRS). This also makes piece production on welding robots profitable. Manufacturers of distinct products such as bars, support beams, railings, stair lifts (Thyssen Krupp), loading platforms (Dhollandia), fork-lift trucks and many other products already use CMRS for piece production. Valk Welding claims to be the only provider of CMRS in the market.

Offline programmes should first of all be verified in practice. Deviations in the positions have to be corrected manually in the programme, which normally takes a lot of time. What is special about DTPS programmes is that they can be used without hardly ever having to make any adjustments on the welding robot. Further features of offline programming with DTPS:

• Importing of 2D and 3D CAD files fully supported
• Powerful programming and testing tools for clamping devices
• Current cycle-time calculations
• Conversion of existing programmes to new systems or other workstations
• Powerful 3D simulation with impact detection
• Planning and management tools for welding work
• Recording of welding data
• Unlimited robot control on assorted production equipment
• 100% upward compatibility with controllers of all generations.
• Easy adjustment of existing robot programmes
• APG (Automatic Path Generation) for DTPS is an open-source software toolkit produced by Valk Welding with which users can develop their own robot software.

Automatic programming with APG

With data from EPR and CAD systems as well as from Excel tables, APF automatically creates complete programmes for the welding robots which include not only the position of the welding torch, but also the correct torch angle and correct welding parameters such as amperage, voltage, oscillation parameters, crater-filling parameters and other parameters.

With CMRS and APG, programmes can be created which are based completely on CAD, ERP or Excel data or data from other systems. CMRS and APG are toolkits developed by Valk Welding for use as plug-ins in DTPS.