igm offers complex customized solutions for automated welding and cutting processes. The product variety for individual applications in the area of robot welding technology is unique throughout the world.
With over 30 years experience in the development of welding robots and in the planning of customer-specific welding production units, we offer an extensive range of system modules.
Welding current Special transfer unit inside of robot axis 1
Cooling system Cooling water circuit up to gas nozzle of torch
Cable guiding Inside, protected
Type of motors Maintenance-free AC servo motors with brakes
Measuring system resolver
The camera is based on synchronized laser scan technology, featuring high speed stability, large and programmable workspace, deep visual range, and robustness regarding ambient light and reflections.
Impassivity against high frequencies and magnetic fields makes it an ideal device for many industrial processes under rough conditions.
The igm laser camera iCAM is mounted on the wrist axis of the robot. It measures the position and volume of the weld groove online and adjusts the robot movement and the welding parameters accordingly. For the purpose of welding in narrow workpiece ranges, the camera can be automatically deposited and readopted during the welding program.This igm developed laser camera iCAM offers as an outstanding feature the complete integration into the robot control. Thus programming is done with the igm teach pendant K6 without the need for an additional PC. The user benefits from the wide range of languages, European as well as Asian ones, being supported by the robot software. By means of the logging function the whole joint geometry can be displayed, indicating gaps and volumes. A live view of the measuring field is given by grey scale value image. Optionally the camera can be mounted to a rotation device, integrated in the robot controller as sensoraxis.
Features of the laser camera, type iCAM
By means of a special software and specifically designed hardware, the "actual" seam position of fillets and V-shaped joints is computed by processing data measured while arc weaving, giving a corresponding shifting of the original programmed point/s to the true seam position.
This arc seam sensing technique can be used with a complete range of welding transfers such as short arc, spray arc and pulsed arc welding - using single or Tandem applications.
By processing data regarding the welding current variation, the robot control system is able to determine the exact welding joint position in 3D during the oscillating welding process. Originally programmed paths are corrected accordingly. The programmed path is corrected on-line in such a way, that the robot follows the joint in all 3 dimensions and keeps the stick out constant throughout the entire welding seam.
Function principle of the arc seam tracking sensor
This online welding seam tracking process is realized by the patented and proven arc controlled seam tracking sensor, type AST.
A built in welding current measuring system via a shunt resistor is permanently measuring the welding arc. The AST sensor card is evaluating the measurement and recording the values at each oscillating point and the middle point. The measurements of the first few oscillating points are recorded and then kept constant throughout the welding joint.
igm - robots with sensor shift
Sensor shifting may be applied for correction of an arbitrary amount of individual points, entire sections of a welding program or entire programs. Combination with arc seam sensing is feasible. The control system supports shifting, rotating, and tilting of a program, depending on position change.
Function principle of the gas nozzle sensor
A control voltage is applied on to the gas nozzle and then a various number of searching runs are performed. As soon as the gas nozzle comes into contact with the work piece, it is discharged and the robot stops immediately. This discharge is recorded on-line by the respective sensor board in the control cabinet and subsequently the robot moves to the next searching run.
After having completed the search runs, the robot controller is shifting the respective program part accordingly.
Sensor program shifts may also be nested, that means, additional search sequences and blocks to be shifted may be programmed within an other block to be shifted.
The sensor shifting feature can be used to correct any number of single points, complete sections of the welding program, or complete programs.
The teach pendant may be used by right and left handed persons and may also be operated in awkward positions.
Following operating languages are currently available by default and can be changed anytime at runtime:
English, German, French, Spanish, Italian, Swedish, Dutch, Finnish, Czech, Hungarian, Chinese, Russian, Korean, Turkish, Polish
As a key element of the RCE control system, the unique teach pendant K6 assembles all the control functions of the RCE control system. No additional keyboard is necessary.
The industrial design award winning lightweight teach pendant is made out of a high resistant plastic mould and a keyboard panel at topside with an embedded LCD touch screen. The sensible buttons are palpable to enable the operator to touch and feel each button even with working gloves on, compared to a touch screen display.
The revolutionary and widely favoured shape of the teach pendant allows a right hand and left operation as well as many other holding positions.
A clear and simple display of each axis button allows the operator a distinctive movement of each axis without pushing the wrong axis button my mistake.
A courser block offers easy navigation in the RCe software menus and replaces any necessary mouse.
The control system is a fully digital controlled system. This means there are only digital signal processors (DSP) involved in the entire control system and not any analogue electronic component. All the components of the control system, such as control cabinet, welding power source, each axis and the teach pendant are linked by a digital bus system.
A full digital robot control system brings the following advantages:
A variety of different rotating and linear units are available, either as single axes or combined with up to three positioning units. It is also possible that several robots share a track axis. The positioning range of a longitudinal axis is up to 100m.
The igm welding robots can be equipped with an automatic torch exchange system, integrated into the hollow shaft of the wrist joint axis.
Due to the hollow shaft in the wrist joint, the various torches (with hose packages coupled) can be fed through. Fixing is assured by a rotation movement.
This unique arrangement offers the following advantages:
All models feature an extremely stable design and (for MIG/MAG welding) integrated water cooling for torch body and nozzle. Torches are mounted at the robot's wrist flange through quick coupling and may be loaded with up to 900A with the tandem process.
Precision The special design with two or four driven rolls allows for integrating the feed in the robot's front axis with single wire and tandem processes. The media feed through the hollow shaft, particularly advantageous for welding applications by allowing almost 720° torch rotation, is also supported for this type.
The built-in, sealed cover reliably protects the feeding unit from contamination during the welding process.
Leading welding technology from single to tandem process
The main application area is the MIG/MAG welding process: the spectrum ranges from single wire to the tandem process, from steel to aluminum, from sand blasted to primed sheets.
Operational availability of the robot installation for production is increased by using an off-line system for generating robot programs. While saving time, programs may be prepared more conveniently in an office environment and simulation test runs (accessibility, computation of cycle time) may be performed. Collisions of the robot with the workpiece or fixtures may be detected at an early stage.
Offline teaching - Online working
Simple robot programming is available through the self developed PC-based off-line teaching system, using the original software of the robot control system and the teach pendant K6.
Offline teaching involves work-piece-oriented programming in 3D mode using a PC and simulation software. The workpiece is first imported into the programming system as 3D-CAD geometry, then the movements of the robot are determined. For path generation and definition of the processing parameters, a number of automatic functions as well as data bases stored in the control system are available.
It is a simple system identical to that for programming the robot system on the factory floor, but with a significant advantage: When the teach pendant K6 is employed, an identical software is used for all calculations. This means that conversions of machine parameters or robot programmes of any kind are unnecessary. All programme changes for the system can be processed using the offline system without any conversion losses.
A laser camera measures the workpiece position and tracks the edges, ensuring requested base heights with a tolerance of +/- 0.5 mm even with heat distortion.
The system processes the required bevels, which are defined by simply clicking and indicating the geometry parameters in a CAD drawing of the component, with the specially developed software.
For the manufacture of hydraulic cylinders, an automatic system consisting of a robot in a closed station with a transport and clamping device is used. Pipes with a diameter between 50 and 100 mm are machined. A library of preprogrammed processes permits a quick change to new workpiece types.
The length of the lift mast can be up to 6 m for large fork lifts. Due to the telescopic design, the masts are of different length and width, but have a similar structure within each family of parts. Thus to modify the robot programs, the igm offline program assembly system iPAT is used, permitting the shifting and copying of program steps or groups of steps on the PC. The geometric data can be read from the CAD system through an interface.
Especially the welding of forks benefits from the consistently high quality of the automation. Despite highly accurate preparation of the parts, the igm robots use a gas nozzle search for position detection and arc seam search to guide the torch along the seam. This is a significant factor in saving costs in the subsequent machining steps by practically
High-quality boilers are clad on the interior with stainless steel sheet metal to avoid corrosion. That means that both black/black and black/white welding joints are required during fabrication. Both joints are handled in a robot cell using an automatic wire changer system. This system permits the complete welding of the boiler in a clamp without manual intervention.
Do you want to automate your build-up welding, do you have to change between MIG/MAG and TIG in your fabrication processes, do you have to weld within a narrow temperature window? We can also take these specifications into consideration in the planning of robot cells and selection of system equipment