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Yaskawa’s Motoman MA1440 welding robot helps ROBOR increase production efficiency with less resources

Photo by ROBOR AG

Photo by ROBOR AG

The long-established Swiss company ROBOR has been producing lifting jacks for over 170 years. In the manufacturing process the quality of the welding seams is of crucial importance. What was formerly a manual task has long since been assumed by robots. Recently an older model was replaced by a Yaskawa Motoman MA1440. With the six-axis robot several plant planning goals can be achieved simultaneously: high stability in arc welding, low costs and a high level of resource savings. The robot thus offers decisive advantages.

Companies such as ROBOR AG, located at Wünnewil near Berne, have become a rarity. Not only has the family business existed for over 170 years. Since its founding is has continued to specialise in the same product group: jacks for various applications. That speaks for the quality of the products, which had already made a name for themselves in the early years. Initially, the main products were robust rack and pinion jacks made of oak. In 1935 steel jacks were added to the portfolio. The practical multi-talents are employed for a wide range of purposes, e.g. at construction sites, in craft trades, for rescue services or the floodgates of hydropower plants. Besides the standard products, specific special solutions are also available, whereby the customer receives support from the design stage to manufacture and installation. The advantages of such jacks compared to other lifting systems are obvious: they are highly robust, simple to operate, have a low deadweight and are independent of power sources.

Premium products rely first and foremost on the high-quality of the welding seams. They were formerly manufactured by hand, but for the past 20 years robots ROBOR has been using a robot for the purpose. Now the time has come for the old model, which simply exceeded its life expectation, to be replaced by a new robot that satisfies current requirements. The management opted for a solution by robot specialist Yaskawa.

Precise and reliable

The basic requirements to be fulfilled by the planned new robot at ROBOR were quickly specified. “It goes without saying that the new robot had to be at least as good as the old one. With this new acquisition we expected a tangible improvement in positioning accuracy and process stability,” explains Stephan Lüthi, member of the management at ROBOR. With the Motoman MA1440 welding robot from Yaskawa ROBOR easily achieved these and other goals. The six-axis robot for arc welding has a high degree of path and repeat accuracy. The new arm design (hollow arm) with central cable routing provides improved accessibility, minimises wear on the hose package and prevents welding errors, because there is no longer a risk of the so-called whiplash effect. In addition, maintenance is simplified. The internal cable routing also prevents cables colliding during welding movements. Besides the high positioning accuracy, that also guarantees welding quality.

“So far we have had excellent results with the Motoman MA1440. Our old robot was always causing positioning problems. Re-teaching was always necessary, and that cost us time. With the MA1440 we have been able to save on several fronts. Due to the much improved repeat accuracy and process stability, our employees hardly ever have to re-teach. The overall set-up time has been substantially reduced. That saves valuable resources and thus hard cash, because welding is of critical importance in the production process. If the welding robot breaks down for a lengthy period or has to be repeatedly re-programmed, the whole production process grinds to a halt,” says Lüthi. Besides that, the slim design of this welding robot is space-saving, benefitting industrial applications. At 6 kg the payload is twice that of comparable models of its class. Another benefit: a wide range of different welding torches and sensors can be installed on the robot.

Stringent quality requirements

The welding process takes on a pivotal role in the manufacture of jacks. Some of the seams are so demanding that they can only be created by experienced welders. Such specialists are difficult to find, and they are also expensive – particularly since the wages are relatively high in Switzerland. The welding robot thus produces a double dividend: it saves wages and at the same time it delivers consistently high quality. Since ROBOR advertises with the promise of ‘Swiss quality’ that is of special importance. These are arguments that speak for a robot not only for large enterprises, but also for smaller companies such as ROBOR.

A further aspect of the decision in favour of Yaskawa was also important: the welding solution should, if possible, come from a single source and be manufactured by an experienced solution provider who is familiar with the needs of companies with welding applications. With the MA1440 and Yaskawa’s positioner R2L250, in combination with a suitable welding unit, Messer Eutectic Castolin Switzerland exactly fit the bill. Messer has been Yaskawa’s Swiss representative for over 32 years and provides both sales and the appropriate service. “I was surprised how fast the two fitters installed the new robot. We were able to resume production after an interruption of only a few days. Yaskawa’s contact partners were present all through the project phase. That ensured ideal planning conditions.” Lüthi continues: “It was clear to see that the experts had an in-depth knowledge of their products. If we had a problem, no more than a phone call was needed and the solution was usually on its way. As a last resort we would only have needed to get into the car, and we would have our spare parts within two hours. That, presumably, will never be necessary, but it gives us peace of mind.”

The double-sided turn-and tilt application of the positioner allows us to weld on the one side while the other side is being reloaded. That saves time and makes the workflows even more efficient. In addition to other savings, additional capacity is also freed up. In combination with short retooling times, that enables additional orders to be completed with ease.

Summary

The Motoman MA1440 is ideally suited to the needs of welding operations with series production. It is easy to operate, fast, has a small footprint and a high payload of 6 kg. High path and repeat accuracy, together with fast refill capability thanks to the positioner with a double-sided turn-and-tilt application, it boosts production results in all areas: improved quality, more efficient production and lower costs overall. In particular for applications that depend on constantly high quality and process stability, investing in a welding robot will pay off compared to a non-automated solution.

For more information, please visit http://www.yaskawa.eu.com.