Product Description
Automatic Robotics MIG/MAG Welding Workstations Welding Large Truck Panels and Floors
Workpiece: Truck, side plates, floor and rear, floor size is about 3293mm*1947mm, rear size is about 1958mm*1458mm,
side plate size is about 3212.3mm*1586.5mm, material Carbon steel, thickness about 2-6mm.
Welding conditions:
Welding method: TIG manual welding for root, filling & cap welding by Automatic welding robot with gas shielded arc
welding Ar (80%) + CO2 (20%) or CO2(100%)
Welding posture: Horizontal welding
Welding wire: φ1.0/1.2mm, solid core or flux cored wire
Wire dry out length: 10mm-25mm
Precision Requirement of welded workpiece:
1. The surface of the workpiece shall not have oil rust, water, oxide film that affects the welding quality;
2. Undercutting accuracy is guaranteed to be within the range of ±1mm;
3. Repeat positional accuracy of the workpiece after assembly is not more than ±1mm;
4. There shall be no flow hanging or burr, etc. that affects the positioning.
Environment condition:
1. Power supply: 3 phs, AC 380V ± 15%, 50Hz/60Hz
2. Ambient temperature: -15~+45ºC, maximum daily temperature difference: 25ºC
3. Annual average relative humidity: ~ 59%, the highest monthly average relative humidity: 90% (+25 ºC)
4. Compressed air: self-produced compressed air from own air compressor, 0.5±0.1MPa if it needs.
5. Geographical altitude: less than 2000m
No direct airflow in the work area which affect the arc welding.
Layout of Solutions:
Brief Introduction:
1. Two separated parts A & B, one Part A for the floor, and another part B for rear and side plates.
2. Part A consist of 2 robots(it's large of welding tasks on floor, we suggest 2 robots, if you need only 1 robot, we can
update it), and 1 welding table with 2 sets of welding fixtures/jigs, one fixtures/jigs is for square reinforcements on single
layer plate of floor, another fixtures/jigs is for the small sealing plates into all square holes of floor. The inner welds
between two layer plates of floor will by tried by robot, if it can't be welded which should be welded by manual due to
small space.
3. Part B consist of 1 robot but 3 sets of welding fixtures/jigs on the table, separately supply for rear and two sides panels.
4. The welding fixtures in each table are integrated with Pneumatic type and manual type together, high-level automation,
if you need simple manual type only, please let us know it.
5. There are hydraulic lifting conveyor roller wheels on each welding table which can assist to move workpieces after
welding work, if you needn't it, please tell us.
6. Each welding table is consist of 4 separated units which easy to butt and assembly together, easy to move and logistics.
Working process(Station A for reference):
1. The worker should do assembly and spot welding for fixing square reinforcements on single layer plate of floor firstly,
then loading it on welding table and fix it by welding fixtures/jigs.
2. One Robot do full welding for square reinforcements on single layer plate of floor, after finish it, manual unloading to
the manual assemble workstation(can use the existing fixtures/jigs the customer have already), at the same time, this robot
can weld new pieces.
3. the work assembly another layer plate and do manual welding inside small space of two layers through the small square
hole. Also assembly the small sealing square plates into each holes, spot welding for fixing firstly, after finish it, manual
loading on the table and fix it by second fixtures/jigs.
4. Another robot do full welding for all small sealing square plates to the holes.
Working process(Station B for reference):
1. The worker do assemble and spot welding for rear, two side panels firstly, then loading on welding table and fix them
by welding fixtures/jigs one by one,
2. The robot do full welding for rear and two side panels one by one, the worker do loading new workpieces and
unloading finished rear and panels at the same time.
KHAW-2000H1 workstation Mainly configurations & Quantity(A):
| Item |
Description |
Quantity |
| 1 |
KUKA brand Industrial welding robot cells KR6R2010(working
reach 2010mm), robot controller and teaching pendant , with arc
welding software package, touch-seeking software package,and other
standard configurations. Multi-layers & multi-passes welding
software(as option but we suggest) |
2 sets |
| 2 |
gantry frame for robot moving(servo motors), L=8m
With safety ladder & platform for human |
1 set |
| 3 |
Welding table(loading capacity up to 2 tons)
With Hydraulic lifting conveyor rollers |
1 set |
| 4 |
Integrated welding fixtures/jigs (for floor frame)
Pneumatic type and manual type together |
2 sets |
| 5 |
Panasonic brand full digital MIG welding source(500A), |
2 sets |
| 6 |
Wire feeder system, Accessories |
2 sets |
| 7 |
Water cooling type welding gun with Anti-collision sensor |
2 sets |
| 8 |
Water cooling system |
2 sets |
| 9 |
Laser tracking system |
2 sets |
| 10 |
Automatic Nozzle cleaner for welding gun |
2 sets |
| 11 |
Smart PLC control system for the whole set, includes wired
remote emergency control box |
1 set |
| 12 |
Accessories (Integrated electric cables, signal control cables, water hose,
wire feeding support frame, wire feeding pipe, gas hose, gas flowmeter, tool
set, and so on) |
1 set |
KHAW-2000H2 workstation Mainly configurations & Quantity(B):
| item |
Description |
Quantity |
| 1 |
KUKA brand Industrial welding robot cells KR6R2010(working
reach 2010mm), robot controller and teaching pendant , with arc
welding software package, touch-seeking software package,and other
standard configurations. Multi-layers & multi-passes welding
software(as option but we suggest) |
1 set |
| 2 |
gantry frame for robot moving(servo motor), L=8m
With safety ladder & platform for human |
1 set |
| 3 |
Welding table(loading capacity up to 2 tons)
With Hydraulic lifting conveyor rollers |
1 set |
| 4 |
Integrated welding fixtures/jigs (for side plates)
Pneumatic type and manual type together |
3 sets |
| 5 |
Panasonic brand full digital MIG welding source(500A) |
1 set |
| 6 |
Wire feeder system, Accessories |
1 set |
| 7 |
Water cooling type welding gun with Anti-collision sensor |
1 set |
| 8 |
Water cooling system |
1 set |
| 9 |
Laser tracking system |
1 set |
| 10 |
Automatic Nozzle cleaner for welding gun |
1 set |
| 11 |
Smart PLC control system for the whole set, includes wired
remote emergency control box |
1 set |
| 12 |
Accessories (Integrated electric cables, signal control cables, water hose,
wire feeding support frame, wire feeding pipe, gas hose, gas flowmeter, tool
set, and so on) |
1 set |
Specifications of Mainly configurations as below:
KUKA KR6R2010 Welding Robot & controller, teach pendant
| Model |
KR6R2010 |
| Number of Axes |
6 Axes |
| Maximum Payload Capacity |
6KG |
| Maximum Working Range |
R 2010 mm |
| Positional Repeatability |
0.04 mm |
| Mass (Weight) |
204 kg |
| Installation Method |
Floor/Wall/Ceiling Mounted |
| Protection Class |
Cabinet IP54, Robot arm IP65 |
| Controller |
KR C4 |
| Controller size |
575*505*490mm |
| Language |
English, Chinese, others |
| Teach pendant |
1.Doing complex action.
2. Match with the robot arm and controller
3. Color HMI interface
4. Support for USB connect, support for remote control,Support Arclink, Ethernet connection,PCMCIA,USB joints |
| Function |
Standard ArcTool; Support for 1 - 6 external axis(option) |
YD-500FT2 full digital inverter pulse MIG/MAG welding source * wire feeder & robot interface
| Model |
YD-500FT2 |
| Supply Voltage Range |
3ph, 380V ± 10% , 50/60Hz |
| Rated Power |
23.3kVA / 22.4kW |
| Duty Cycle (40 °C) |
60%550A; 80 %520A; 100%550A |
| Rated Output Current |
500A |
| Output Current Range |
60 - 550 A |
| Output Voltage Range |
17 - 41.5V |
| Maximum No-Load Voltage |
70 V |
| Dimensions (L x W x H) |
780 x 375 x 625 mm |
| Weight |
78KG |
| Protection Class |
IP23s |
| Welding type |
CO2/MIG/MAG, digital inverter pulse |
| Wire feeding device |
Panasonic Double-driver with encoder,
for Φ1.2/1.4/1.6mm |
| RM82W Welding gun |
Water cooling type |
Water Cooling System:
Power 220V±10% AC
Tank capacity approx. 9L
Water column 35m/5L/min.
Cooling capacity 1500W (1L/min.)
Dimensions (L x W x H) 480 x 280 x 380mm
Weight 16.5kg
| Power |
220V±10% AC |
| Tank capacity |
approx. 9L |
| Water column |
35m/5L/min. |
| Cooling capacity |
1500W (1L/min.) |
| Dimensions (L x W x H) |
480 x 280 x 380mm |
| Weight |
16.5kg |
Gantry Frame
Servo motor drive, Quick moving & stable positioning
X=10m with servo motor, Y=2.2m
X axis Height 2.3m
Loading weight: 500kg
Customization
With safety ladder & platform for human
Welding Table&base platform (for floor frame)
Loading Weight 1tons, 2tons depending on customization
Repeatability ±0.1mm
Size(L*W*H) 8500*2200*600(mm), includes 4 separated units
Total Weight(about) 2200kg
Option Conveyor rollers ≥12 pcs, Hydraulic lifting
Integrated welding fixtures/jigs (For floor frame)
Total 2 sets
Customization, fast operation type
With Pneumatic type and manual type together
AirTac brand Pneumatic components set ≥4 pcs
Compressed air: 0.5±0.1MPa if it needs.
Welding table & base platform(For rear, side plates)
Loading Weight 1tons, 2tons depending on customization
Repeatability ±0.1mm
Size(L*W*H) 8500*2200*600(mm), includes 4 separated units
Total Weight(about) 2200kg
Option Conveyor rollers ≥12 pcs, Hydraulic lifting
Integrated welding fixtures/jigs (For rear, side plates)
Total 3 sets
Customization, fast operation type
With Pneumatic type and manual type together
AirTac brand Pneumatic components set ≥12 pcs
Compressed air: 0.5±0.1MPa if it needs.
Laser tracking system:Can help the robot stay work at the right weld position easily when the workpieces' seam
accuracy is not good, to improve the working efficiency.
Automatic welding nozzle cleaner:Four functions:
-Cleaning gun
-Wire cutting
-Positioning calibration
-Lubricant fuel injection
Smart PLC control system, external wired remote control boxes:
Includes external wired remote control boxes, Alarm lights
PLC: Siemens/Delta
HMI: Siemens/Delta
Isolators & terminals: Siemens/Schneide / MEANWELL
Servo Motor & Drives: Siemens / Siemens / Huichuan/Delta
Low Voltage Components: Siemens /Delta
Others: Chinese famous brand
Accessories:Integrated electric cables, signal control cables, water hose, wire feeding support frame, wire
feeding pipe, gas hose, gas flowmeter, tool set, and so on
Option parts:
Safety fence Safety encoder & sensor
Multi-layers &Multi-passes welding software package
Welding dust extrctor Suction hood & curtain
Industries application:
Tanks, Boiler, Heat-exchangers, Pressure vessels, Oil, Gas, Food, Beverage, Water treatment, Medical,
Petrochemical, Automobile, engineering vehicle, mining machinery, navigation crane, construction steel structure,
bridge steel structure, and other industries.
Detailed Photos
Packaging & Shipping
Packaging: wooden case
Shipping: by sea, by truck or by rail.
FAQ
1.Can I purchase products which are not shown on the website?
Yes. Please send us your detailed requirements and we will try to help with your specific needs.
2.How can I place an order?
You can contact us by email (see contact page).
3.Where do you loading the goods?
Shanghai or Ningbo or Qingdao or Shenzhen port, etc.
4.How to make payment?
You can pay us by Paypal, L/C ,T/T and West Union,etc.
5.What is the type of our transportation?
As your requirement, by express, truck, rail, by sea or by air.
6.Can you offer the customers product sample?
Yes .After receiving your inquiry , we will arrange to send the sample within 3 days.
7.How do you pack the goods ?
According to customer's request.
8.What is your payment terms?
FOB Shenzhen, Guangzhou, Qingdao, Shanghai /Ningbo or other city in China , Or CIF Destination.
9.Can you also offer the service with OEM and ODM ?
Yes. We can offer OEM/ODM service. Please send us your brand information and specification.
10.How long is the warranty of your products ?
Generally, it's one-year-warranty. During the warranty period, we offer you free maintenance.
After the warranty time, lower price for customers buying breakdown parts.
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