Welding station

Welding is one of the primary operations in the production of stamped and welded metal components for heavy equipment, automobiles, appliances and more. Today, the labor market suffers from a shortage of skilled welders, and the first to be severely affected are SMEs.
There are many job opportunities for these companies, but they are often turned down because the number of welds required to complete the job order is too high and impossible to ensure due to the small internal team of welders.
This difficulty is compounded by that of traditional welding automation technologies, which are rigid and unable to cope with productions characterized by low volumes and high product mixes.
We also remind you that there is exposure to harmful fumes during welding operations. Intense exposure can in fact cause irritation to the eyes, nose and throat, not to mention dizziness and nausea, and if prolonged over time, damage to the lungs, kidneys, nervous system and even, depending on the fumes, the development of forms of cancer.

Many SMEs, tired of losing orders, have decided to approach the possibilities offered by collaborative robotics, able to propose flexible solutions and able to manage even short batches with a high mix.
With collaborative solutions, there is no need for cages or protective fencing around the applications, making them small and compact.
Many SMEs already have traditional robots to perform welding, but these are rigid, non-collaborative solutions that require special tooling and safety devices that can take a very long time up to 16 weeks to build. Moreover, especially when applied to small parts, and short batches, traditional robots are poorly profitable.
The collaborative welding application delivers real results, including quality consistency that even the most experienced manual welders can’t achieve.

Welding station

With Doosan Cobots it is possible to carry out MIG/MAG or TIG welds on specific analysis of the application requested by the customer. Thanks to the possibility of connecting the welding machine to the cobot and communicating specific on/off points, it is possible to achieve exceptional welding quality because itis possible to set the individual welding seams to be produced with extreme precision: this eliminates the uncertainties and process drifts that end up affecting the final quality of the process.
Currently, the options for configuring the welding station with Doosan Cobots are available for the A SERIES, with a maximum payload of 9 kg (including the weight of the gripping tool) and 1200 mm outreach, for all versions of the M SERIES, by applying the appropriate protection, and for the H SERIES, with a maximum payload of 25 kg (including the weight of the gripping tool) and 1700 mm outreach.
The available welding path options are also extensive and range from the ZIG-ZAG configuration, with the possibility of controlling the amplitude of the wave and the speed at which it travels through a period; CIRCULAR, with the possibility of modifying separately the two amplitudes and their respective speeds; SYNOSOIDAL, with the possibility of modifying the amplitude and the period; and TRAPEZOIDAL, with the possibility of establishing a welding time from P1 to P2 and a different one for going from P2 to P1, as well as for accelerations and setting a rest time after reaching the points.

In contrast to a traditional industrial robot, cobots are also characterized by their simplicity of programming; in fact the operator can manually move the collaborative robot on the component to implement the integrated self-learning function of the Cobot, which stores the welding trajectory and the start and end points, creating a program in just a few minutes. As long as the robotic welder program is running, it is not necessary to use qualified welders to oversee the operation. It is thus possible to solve the problem of shortage of qualified and specialized personnel without giving up high quality, continuing to grow as a company. Moreover, operators are protected and relieved from carrying out operations that are often uncomfortable or unhealthy, such as welding, which exposes workers to glare, inhalation of toxic fumes, or intense electromagnetic fields.