Flexible Welding Cell

challenge

A flexible welding cell had to designed and built for low volume production runs of more than 100 different part types. Additional requirements included automated rapid changeovers of less than one minute, cycle times of (3) seconds per weld, eliminating the need for operators to move heavy weld fixtures, focusing on quality control for different part materials and thicknesses, and improving weld consistency.

solution

Working with our customer during ongoing process development during the design and build of the machine, JR created a solution to meet all requirements. The JR solution uses a material handling robot to pick a fixture from a rack and present it to an operator for part loading. The robot then presents it to the weld gun. This method reduces part changeover from hours to seconds, while ensuring future product lines will only require additional fixtures.

The robot does the heavy lifting—this full automation solution needs only one operator. Additionally, this flexible JR process reduces the overall number of fixtures, weld points per part type, and number of weld tips from 20 to 1. Finally, full automation increases consistency, and our carefully researched weld power supply improves quality across various metals.

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outcomes and benefits

Process development beyond the quoting stage, Fewer fixtures and weld tips, Consistent weld quality for wider range of part materials and thicknesses, Fewer welds per part, Ergonomic design and optimized workflow, Cost savings justified the purchase of a second cell within the first year

JR Solution Leads to Cost, Time, and Operator Savings for Customer

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Industry

Consumer Products

Technical Capabilities

Material Handling Solutions Robotics Integration Welding Applications

Region

From the client

"JR designed and automated a flexible welding cell for low volume production runs of more than 100 different part types."

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