HOPF GmbH increases productivity and weld quality with PANASONIC welding robot system

The demands placed on the metalworking industry are increasing rapidly. More complex workpieces, growing time pressure and a noticeable shortage of skilled workers are presenting companies with ever greater challenges. Hopf GmbH is addressing these developments by taking a decisive step towards the future, investing consistently in modern automation technology.

In its search for a future-proof solution, Managing Director Engelbert Hopf discovered the right approach at a trade fair. Working together with automation specialist ERL, the company developed a tailored concept to optimize its welding processes: the implementation of a state-of-the-art ARCentre XPERT robotic welding system.

Challenge

The metalworking industry is under increasing pressure. More complex workpieces, tighter production schedules and the continuing shortage of skilled workers are driving the need for more efficient manufacturing solutions.

Solution

A future-proof robotic welding system designed to relieve skilled workers, ensure sustainable process and product quality, and enhance the company’s attractiveness as an employer.

Automation at Hopf GmbH

The ARCentre from our partner ERL GmbH performs MIG/MAG welding using standard, pulse and special pulse processes, with a maximum reach of 2,011 mm. In terms of welding technology, the system features an integrated 450 A Panasonic TAWERS welding power source combined with a water-cooled DINSE torch system. The TAWERS system integrates the robot controller and welding power source into a single unit.

At the heart of the new installation is the Panasonic TM-2000–WG3 welding robot, which enables flexible welding of components on two alternating workstations. Depending on the application, the stations can be configured either as a single-axis rotary positioner for machining long workpieces or as a tilt-rotate positioner for components requiring synchronized positioning during welding. The positioners can accommodate workpieces weighing up to 500 kg and are designed for welding current transmission of up to 500 A. Thanks to the identical arrangement of the positioning units on both stations, welding programs can be copied seamlessly from one station to the other.

To ensure optimum positioning relative to the workpiece, the system is equipped with an almost 8 m long travel track. Integrated into the track are all required utility lines, including power and compressed air, as well as the Rolliner wire feed system.

Reliable wire delivery to the robot is ensured by the Rolliner wire feed system. Its pairs of feed rollers, offset by 90° from one another, guide the welding wire particularly smoothly, ensuring excellent arc stability. At the same time, wear and the associated maintenance requirements are significantly reduced. This also eliminates downtime for wire spool changes, particularly when using 250 kg wire drums positioned outside the system. In addition, the need for a separate wire tender cart is eliminated, reducing both costs and floor space requirements. Another advantage is the integrated quick-change system, which allows operators to switch between drum and basket spool holders without tools, enabling special filler materials to be processed on the robot quickly and flexibly.

The system also features an automatic torch cleaning station to ensure a smooth welding process. Its integrated reamer reliably removes weld spatter from the nozzle before anti-spatter agent is automatically applied. This maintains consistently high weld quality while significantly reducing unplanned downtime. In addition, the integrated water cooling system provides fast and reliable control of the torch coolant temperature, protecting wear parts and significantly extending their service life.

For further information visit: https://eu.connect.panasonic.com/gb/en/case-studies/technology-delivers-new-production-opportunities-hopf-gmbh-arcentre-welding-robot-our