GENESIS CNC ROBOTIC WELDING & GRINDING WORKCELL DESIGNED FOR

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3
The four corners of formed, stainless steel panesl are to be robotically
welded. The welds are then to be robotically ground such that the major
ity
of the weld is removed. The final edge finishing will be manually perfo
rmed
outside of the Genesis System.
The system will be configured with (5) sets of change-out details for th
e
weld station tooling as well as the (5) sets for the material removal ro
bot
gripper. The material removal robot gripper also features an automatic
changeover of gripper tooling per family of parts.
WORKCELL DESCRIPTION
A preliminary system layout of the three robot system is shown in Figure A.
One operator per shift will be required to load and unload the system.
The
operators is also responsible for the removal of the laser film at each
of the four corners. The raw panels are inserted into the machine throu
gh
a vertical slot in the fence. The laod station includes a pair of power
ed
conveyors that will move the raw panesl into the welding cell. This is
a
modification from the original proposal. Tooling will maintain the
orientation of the panels and verify proper load. A camera will verify
whether the correct part is loaded in the proper orientation by comparin
g
the panel position to a pre-defined pattern. Once the part is identifie
d,
Robot 1 picks the panel from the load station with a pneumatic (vacuum)
gripper. Robot 1 then transfers the panel to the weld fixture. The pan
el
is placed onto a weld fixture that locates the interior profile to the c
orner.
Automatic clamps hold the panel in place, and then Robot 1 opens the gri
pper,
releasing the panel.
Once Robot 1 is clear of the weld path, Robot 2 begins to weld the corner
that is fixtured in the weld station. During the weld process, Robot 1
moves
to an adjacent corner of the panel and waits for the welding to finish.
Upon
completion of the welding, Robot 1 closes its gripper and holds the pane
l while
the weld fixture clamp release. Robot 1 then rotates the panel such tha
t
another corner is placed into the weld station. This process continues
until
all four corners are welded.
Cont. on
3
WORKCELL DESCRIPTION (Cont.)
Robot 1 transfers the finish-welded panel through a sliding door between
the welding and grinding zones of the system and signals Robot 3 to take
the
panel. Robot 3 engages the panel with a gripper similar to the welding
fixture,
and Robot 1 releases its gripper. At no point is the panel set down dur
ing
the transfer.
Robot 1 returns to the load station to pick up ram panel.
Robot 3 manipulates the welded panel against a compliant servo beltstand
one corner at a time. Once each corner weld is ground, Robot 3 sets the
part into a nesting fixture and reorients to hold another corner. This
process continues until all four corners are ground. A dust collector
is included in this proposal. It will be ducted from a point under the
belt sander to the inlet. The exhaust will be returned to the cell. Ro
bot
3 then trnsfers the finished panel to the unload station and releases it
.
The part rolls through the safety fence to a pickup point near the load
station.
Changeover among the different model panel is minimal. The weld tooling
requires the operator to remove the fixed locating details and replace t
hem
with the set that matches the part width. All clamping and sensor conte
nt
remains on the fixture base. The gripper for Robot 3 includes an automa
tic
tool changer that allows for the gripper to be changed out without opera
tor
intervention. Once the model panel is selected, Robot 3 will automatica
lly
select the correct gripper details from a rack.
WORKCELL COMPONENTS
(2) Large Robot Platform Bases (with "Part Transfer Door" Option)
(2) Process Platform Bases (Material Removal, Robotic MIG Welding)
(2) Control Pallets
(2) Fanuc R2000iF Material Handling Robots
Ethernet I/P Interface
(1) Fanuc ArcMate 100iB MIG Welding Robot
Ethernet I/P and DeviceNet Interface
Cont. on Page 3
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WORKCELL COMPONENTS (cont.)
(1) Fronius CMT Welding Package
(1) Pushcorp SBS-81 Servo Belt Stand
(1) System Control Package
Allen Bradley Compact Logix - based PLC Controls
Ethernet I/P Interface to Periferal Devices (including Robots)
Cognix / DVT Camera Package with Lighting
PanelView Plus 700 Operator Interface
(1) Infeed Conveyor with Tooling
(1) Outfeed Conveyor with Tooling
(1) System Safety Package
Dual Channel E-Stop Circuit (RIA compliant)
Complete Fence Package with Interlocked Gates
(1) MH Robot Gripper Package (Robot 1)
Pneumatic Gripper with Open/Closed Sensing
Part Present Sensor
(1) MH/MR Robot Gripper Package (Robot 3)
Pneumatic Clamping
Robotic Rotary Joint for Cable Management
Tool Changer Master Plate
(5) Tool Changer Master Plates
Tool Change Station (5 Nests)
(1) Weld Tooling
Weld Fixture Base Unit
(5) Sets of Manual Change-Out Details
(2) Permanent Weld Fixtures for Part Number 0186560
Pneumatic Clamping
Part Present and Clamp Open/Closed Sensing
(1) Environmental Package
Torrit DRO 2-2 Dust Collector
Grind Dust Ducting
3' x 2' Smoke Hood with Ducting ("snorkel" exhaust could replace hoo
d
depending upon final system layout)
hs**