Figure 1: The fully automated robotic welding work cell, with all actions managed by an AutomationDirect Productivity PLC, synchronizes the welding process, robotic motions, and component positioning.
Source: Properly WorksWhen a business known for its expertise in welding and steel fabrication protected a contract to supply fencing for building of a bridge, there was no time at all to lose.
Faced with the overwhelming job of producing over 3 miles of fencing within 90 weeks, it turned to Properly Works, a systems integrator with a tested record of enhancing production operations with automation and robotics, to help develop a service that would not only decrease the general project timeline, but likewise yield high-quality results.A typical section of bridge fencing includes 16 steel pickets protected with over 140 welds.
When done by hand, each sector required roughly 10 hours for setup and welding.With years of experience as a market leader in commercial welding and steel fabrication jobs such as this, Lancaster, N.Y.-based Seibel Modern knew that an essential to success would be making the most of effectiveness.
Recognizing the advantage automation would bring to this laborious procedure, work started to make use of a collective welding robot and establish an automatic component to increase efficiency.Implementing a tabletop-type robotic arm with a welder was the initial strategy, however it was quickly identified that more considerable automation would be needed.
Elma Center, N.Y.-based Properly Works approached the project by working together with the fence producer to incorporate formerly independent systems into a completely automated robotic work cell (Figure 1).
The difference was undeniable—-- an amazing 12-1 reduction in time, with the included benefit of minimizing touch up work by 50%.
To better value the successful results, we’& rsquo; ll take a closer take a look at the approach that made it possible.Collaborators bridge understanding gapsWith the clock ticking, this would be a collaborative task.
Properly Works and Seibel Modern worked to develop a specification, with Seibel defining the welding geometry and requirements and the fixturing, while Properly Works applied sensors and automation for optimal operation and safety.Drawing on its metalworking competence, Seibel Modern produced the welding component powered by Properly Works’ & rsquo; servo motor driven rack-and-pinion mechanism to position the robot for welding.
The fixture included clamping and horizontal-to-vertical positioning utilizing a hydraulic lift.Synchronization of motion with the gantry positioning system for the robotic welding arm was a core requirement to the design.Welding task requires orchestrated productionPutting the pieces of each independent system together needed a thoughtful combination technique.
The innovative digital welder required to communicate not just with the smart robot, however also the systems controlling the welding component, the workcell safety systems, and the operator controls.The style likewise needed the versatility to adjust to various fence section setups.
A programmable logic controller (PLC) was figured out to be the ideal genius for the application, managing the movements of each control subsystem.As an independent systems integrator (SI), Properly Works releases these systems using a variety of brands for robotics, welders, motion control systems, and basic commercial automation products.When there are no preliminary defined requirements driving the work, Properly Works normally chooses selecting AutomationDirect‘& lsquo; s portfolio for automation and motion control due to the detailed variety of items, ease of choice, usage, and support, and the exceptional price/performance ratio.Figure 2: An AutomationDirect Productivity 3000 PLC provided the programming, memory, and interactions capabilities to manage the SureServo2 drive with the robotic welder and other automation.
Source: Properly WorksFor this project, the AutomationDirect Productivity 3000 PLC was picked as the controller for the robotic work cell for its adaptability and scalability (Figure 2).
A plethora of functions and functionality, integrated with large storage capability and EtherNet/IP communications all factored into this choice.
This PLC would coordinate movement through an AutomationDirect SureServo2 system.With hardwired input/output (I/O) signals, as well as IO-Link linked discrete signals, and Ethernet and serial digital interactions, the PLC quickly interfaced with all robotic functions, the digital-based welder, safety systems, the hydraulically operated welding fixture, and the motion-controlled gantry system for positioning the robotic arm.The SureServo2 drives a pinion gear which moves the gantry rack, and the Productivity PLC has the processing power and native movement control operates to command accurate motion while flawlessly incorporating and coordinating with the automation and robotic components.The PLC also engages with an AutomationDirect C-more human-machine user interface (HMI), for complete visualization of the system.Within any robotic work cell, security is paramount.
Although the Productivity PLC does not have native safety-rated functions, it interfaces with dedicated security elements that are hardwired to develop a work cell safety circuit.Several security products were used in the style including Dold security relays for keeping track of the safety circuit, Datasensing safety light curtains (Category 4, Type 4) to find invasion into limited areas, and both mushroom pushbutton and cable-pull safety switches emergency situation stop (e-stop) devices.The cable television pull can be set off from any place along the cable length, supplying a hassle-free precaution inside the work cell where an e-stop button may not be within reach.To ensure the quality of the ended up product, accurate positioning of both the robotic and steel pickets is vital for each fence section.
During the welding process, the SureServo2 system manages a rack-and-pinion linear actuator to properly position the robotic throughout 9 ft.
of linear travel.The PLC manages the robot’& rsquo; s position along the linear gain access to, along with 6 additional axes of motion on board the robotic arm itself.
The start and stop points for each weld are figured out by the PLC, utilizing feedback from the SureServo2 system and servo encoder sensor.
Software limitations are imposed to protect against over travel.Now accepting session submissions!Special cases spark creativityAlthough a vast bulk of the fence segments were standardized, it was periodically needed to build and bond unique segments, for instance a partial sector with half the number of pickets.
The PLC made it simple for Properly Works to develop a program able to accommodate variations in fence segments.For each special case, a “& ldquo; recipe & rdquo; alternative was developed within the programs reasoning.
Similar to how recipes are used at the same time industry, utilizing a dish technique made it simple for the operator to dynamically configure the size and type of each fence segment.To preserve consistent, premium welds throughout the process, the system was designed to attend to the impacts of splatter from arcs and sparks on the welding nozzle by using an automated reamer to occasionally clean debris from the welding nozzle.In this application, it was more efficient to start the cleaning function timing and sequence straight from the PLC.
This enables the PLC to send the robot to the cleaning station at the most hassle-free times during the procedure after a specific number of welds are completed, optimizing performance while reducing weld defects and saving consumables.The voltages and currents used during welding operations cause the existence of high electromagnetic interference (EMI) and radio frequency interference (RFI).
To make sure reliability in this harsh EMI/RFI environment, protected cable televisions and accessories like EMC cable clips, were used to safeguard the electronic equipment in the workcell.Welding on the (graphical) fenceOne of the notable functions of the system is the intuitive operator interface.
Constructed on the C-more HMI panel, the color touchscreen user interface is effective yet easy to use.
The HMI includes a visual representation of each fence sector (Figure 3), highlighting the position of each weld.The welder has digital fault detection, efficient in noticing process conditions that will cause a weld problem such as incorrect present or voltage, absence of gas, or the end of a wire coil.
When a procedure abnormality is spotted, the system will flag the weld.
This is visible on the HMI and makes it easy for the operator to return the system to the home position and reinitiate the weld.The operator also has the capability to flag any weld through the HMI while they are observing the procedure.
In addition, the welder can pick specific fence posts, or even particular welds, to either consist of in the welding procedure, or leave out.
This allows operators to do rework as needed after inspection.Figure 3: The C-more HMI shows each weld, with a flagging system to easily mark and identify process problems, enhancing performance, streamlining rework, and increasing general quality.
Source: Properly WorksClient sees substantial, quantifiable resultsThe client was impressed with how simple the system was to run, and it discovered that any flooring staff member might successfully run the devices after very little training.
With the brand-new automatic system, a single fence sector might be produced in 45 minutes —-- an unbelievable enhancement from the initial 12 hours!Furthermore, weld defects were decreased, reducing the need for touchup work by more than 50%.
With shown results from the initial workcell, the whole operation was expanded to a total of 3 systems to increase throughput and maximize operations.With the tight task timeline, Properly Works turned to AutomationDirect for many job automation needs consisting of the PLC, HMI, servo system, electrical items, and security elements.
The website provides stocking openness, so it was simple to select and directly acquire products that fit the technical requirements and timeline without the additional trouble of getting quotes for numerous products through several distributors.Both technical efficiency and business elements have raised AutomationDirect to be the preferred supplier for Properly Works.Based on this project exceeding all objectives, the customer is now excited to pursue extra automation jobs with Properly Works.
With the best integration partner and smart innovation, even the most difficult production difficulties can be overcome with speed and precision.About the authorDominic Myers is the president of Properly Works, leading a cross-functional team supplying automation solutions for basic manufacturing and food production.
He has more than 25 years of experience in organization method, item advancement, and market expansion, and a proven track record of providing innovative, lucrative services throughout diverse industries.Myers is on the Industry board of advisers at Buffalo State College, and the board of directors at the Buffalo Niagara Manufacturing Alliance (BNMA).
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