Cycle time reduced by 30%

There is cutthroat competition in the trailer building sector. System Trailers in Twist, Germany, has gained a distinctive position as an independent producer of trailers and semi-trailers. The factory produces 60 to 70 trailers a week. 70% of the company's turnover is generated.outside of Germany. Director Ralf Saatkamp: "Our strategy is to make favourable purchasing conditions and highly efficient production processes possible by combining the demand of several truck manufacturers. That way we can offer our clients consistently high quality and favourable prices." System Trailers has geared its organisation, production and computerisation entirely to a large variety in a high volume production setting.

Three identical welding robot systems

Two years later Valk Welding has delivered another two of the same welding robot systems. All three welding robot systems are set up to weld longitudinal beams with a standard length of 13.65 m. The last two welding robots are positioned next to each other in a right and left hand version. Beams welded on the right-hand welding robot are automatically tilted and transported to the other welding robot system, where the other side can be welded. It is partly as a result of this logistical automation that System Trailers has succeeded in reducing its lead time for the girders by 30%.

Automatic programming

Our aim is to continue to increase our turnover. We currently have one single employee spending only 2 days a week on offline programming in DTPS. But we still want to integrate the programming more closely in the workflow. With that aim in mind we are now working in intensive partnership with Valk Welding to automate the programming of the welding robots with APG (Automated Program Generation) based on CAD data, linked to ERP. In this area, too, Valk Welding’s approach was clear. As well as its know-how, this also includes motivation, innovation and the flexibility of coming up with solutions.

Weld seam tracking with the Arc-Eye laser sensor

The next step is to use the Arc-Eye welding seam tracking system. The tolerances,differences and tension in the product that occur during the welding process make it necessary to check whether the position of the welding seam corresponds to the programmed position. Deviations cannot be predicted, which means that the programme can only be corrected afterwards. For this purpose Valk Welding uses Quick Touch (wire searching) and Arc-Sense to locate and then track the welding seam. To speed up that process and further improve the weld quality, System Trailers will be using Valk Welding's Arc-Eye weld tracking system. The Arc-Eye laser sensor is mounted in front of the welding torch and carries out circular scans to make a complete 3D image of the welding seam. Ralf Saatkamp: “That way the Arc-Eye system ensures that the welding robot precisely tracks the welding seam so that a reliable welding seam is made. This has also made it possible for us to take another step towards reducing the cycle time over 13.65 m.
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