Skip to main content

Universal Robot Programming System for Small-Batch Manufacturing of Products with Large Dimensions and Several Thousand Spot and Arc Welds

Objective

To develop an off-line programming method for automatic welding of large structures (as train carriages, bus chassis, bogies etc.). It will be used to program a mobile robot with an automatic gun changer to make up to several thousand of arc welding spots.
An off line programming method for automatic welding of large structures has been developed. It will be used to program a mobile robot with an automatic gun changer to make up to several thousand arc welding spots. The novel approach is to subdivide the structure to be welded into cubes, where each cube contains all the required data for the welding process. Communication requirements have been specified, to enable an effective exchange of process data within the automated workcell. A prototype will establish an appropriate computer integrated manufacture (CIM) system architecture.

Several intermediate results can already be exploited, such as a new automatic tool changer; new criteria to design jigs and fixtures for large structures; how bogies can be correctly clamped in spite of their complex geometrical configuration, and a software tool applied to the cubes' subdivision method.
The novel approach to be adopted is to subdivide structure to be welded into cubes, where each cube contains all the required data for the welding process. Communication requirements have been specified, to enable an effective exchange of process data within the automated workcell. A prototype will be made in order to establish an appropriate CIM system architecture. Finally an integrated sensing system will be tested in industrial conditions, to determine the suitability for automated welding cells, basically dedicated to railways manufacturing (waggons) and further to caches and heavy trucks.

Several intermediate results can already be exploited, like a new automatic tool changer, new criteria to design jigs and fixtures for large structures; how bogies can be correctly clamped in spite of their complex geometerical configuration, and a software tool applied to the cubes 'subdivision method. A pilot demonstration is foreseen aiming to link all elements of the welding process by a network i.e protocol for data interchange, data transmission high speed, reaction to deviations from the planned working process.

Coordinator

BISIACH & CARRU SPA
Address
Corso Lombardia 21
10075 Venaria
Italy

Participants (4)

Fiat Ferroviaria
Italy
Address
Piazza Galateri 4
12038 Savigliano Cuneo
Gesellschaft für Automatisierung, Prozessteuerung und Schweißtechnik mbH
Germany
Address
Reutershagweg 4
52074 Aachen
SOREFAME
Portugal
Address
Apartado, 6
2701 Amadora
WAGGONFABRIK TALBOT
Germany
Address
Julicher Straße 213-237
52070 Aachen