Valk Welding supplies robot for complex aluminium tube constructionsPrint this page
Based on years of experience and over 700 of installed welding robot installations, Valk Welding, one of the most successful robot integrators for welding in the Benelux, has recently supplied a welding robot installation for the welding of complex aluminium tube constructions in a 7000 alloy. The installation that Valk Welding has developed for the Belgian supplier Wilmar, consists of a Panasonic welding robot on a track of five meter and two clamping stations. The mould in which the aluminium tube constructions are being clamped and rotated between a manipulator and counter bearing, has been developed by the customer.
Wilmar produces among others aluminium framework girders from tube material (lengthy tubes + shores) with a large wall thickness and a length of 2.4 m. Wilmar was searching for a robot solution to be able to make the product at competitive prices. One of the paramount requirements demanded by the supplier for the end result was a high tensile force for the girder. The use of the MIG/MAG welding method to weld aluminium has in the meantime reached such a development stage that a good end result can be guaranteed with a high production output. The expansion of the material due to the heat development during welding, forms another limitation. Especially with complex constructions, with several connections and little space in between, size deviations are caused resulting in positioning problems. Valk Welding completely mastered this problem for this project mainly by focussing on the welding sequence, the parameter settings, the tolerance pieces and the position of the clamps. As important was the reachablity of the robot used.
Saving time
The robot installation is employed in a one shift service. The cell is welding end-pieces to the lengthy tubes in one clamping place, and the complete product in the mould in the other clamping place. The framework girders are being welded in one fifth of the time required for manual welding of the aluminium framework girder. For the future, the supplier is thinking of using more shifts or to expand with a second welding mould to increase the robot welding duty. Wilmar is extremely satisfied with the appearance. The weld is constant and does not contain sharp weld splashes that might hinder its use. The oxide deposit is removed by hand when carrying out the visual end control.
(Source: various professional magazines Sept. / Oct. 2001)