Robotic Production Welding
Bossong Engineering operates eighteen robot welding and cutting systems with a current fabrication capacity exceeding 5000 ton per annum. These systems offer significant advantages over manual welding as follows:
- Precise welds of uniform size and quality.
- Constant uniform heat input minimising distortion.
- Improved productivity.
- Reduced welding personnel fatigue.
- Improved welding personnel safety.
All robot systems are fitted with Gas Metal Arc Welding (MIG) systems. The latest technology in pulse welding power sources perform high quality spatter free welding on carbon steel, various grades of stainless steel, aluminium and exotics. Other welding processes such as Submerged Arc and Plasma Welding are employed when required.
Since the robot cannot see like a human welder, parts consistency is vital to take full advantage of the speed and accuracy of welding robots. Although advanced touch sensing and seam tracking systems enable us to cater for cut variation or thermal distortion in parts the process reduces production rates.
Qualified welding inspection personnel develop welding procedures and inspect welded product during manufacture and before dispatch to ensure welding.
Robotic Welding Systems
Our latest robot welding systems has the manipulator inversely mounted, maximising the working envelopes as compared to mounting it conventionally. Furthermore the base of the robot manipulator is mounted on a servo driven track that allows the work envelope to move up to 10 metres. The whole system is enclosed and divided into two or three working cells depending on the job. Personnel can only move between cells via the doors while the robot manipulator retracts and moves along the top rail above the dividers. Operators can load and unload parts in one work cell whilst the robot is welding in another simultaneously. This means the robot is continuously welding and not having to wait for operators to load new parts and vice-versa. During welding the operator is isolated from the welding robot at all times eliminating any hazards. All doors around the enclosure are fitted with the latest safety sensors to ensure that the robot stops completely once a door is opened. Significant improvements in safety and productivity have been achieved through this system.
The fixtures which hold the parts for welding are secured to a servo rotator which orientates the job to the optimum position for welding. The rotator and the robot is cable of synchronous motion.
Robot Specification:
Maximum Continuous Weld Length: 9.5m
Maximum Weight Capacity: 6 ton