Robotic Frame Welding

Project summary

MWES provided a Standard Ferris Wheel Welding Cell to our customer, for the final welding of generator base frames. This system included a robot and a 2-sided, interchanging, welding positioner, as well as custom-designed fixturing. 

The Challenge

Due to a shortage of trained welders and the high costs associated with acquiring them, this firm required an automated solution that would give them improved cycle times and throughput without the need to acquire more costly welders.

The Solution

MWES provided this firm with an automated robotic welding solution that allowed the operator to tack together their parts on the positioner, as well as have them fully welded by the robot.

The sequence of operation included the following:

  • The operator scans the barcode on the computer monitor which signals to the robot which program to call for the next frame to be welded
  • The operator loads a frame into the operator side of the Ferris wheel positioner located in the weld cell, if a tooling change is required the operator would change the tooling to the corresponding needed setup
  • The operator tacks members as needed and retracts clamps as required
  • The operator verifies correct loading and leaves the station
  • The operator presses the cycle start, acknowledging the completed loading of the station and that the system is ready for the automatic cycle. While there are light curtains and a scanner in the operator load station it is ultimately the operator’s responsibility to ensure there are no persons or obstruction in the station which could inhibit the automatic cycle of the system.
  • When the system is available the Ferris wheel positioner will index the loaded part into the weld station, the index takes less than 4 seconds then weld cycle begins
  • The welding robot begin welding the frame; the positioner will rotate the frame for accessibility to the bottom side as needed
  • Once the index is complete the operator will enter the load area and repeat the loading/tacking process for the next frame
  • Upon completing the weld cycle the weld robot will retract away from the welded frame
  • The Ferris wheel positioner will index the loaded part into the weld station, while simultaneously indexing the welded part out of the weld station
  • The robot will begin welding the next part
  • Simultaneously the operator will unload the welded part and will load/tack the next part as needed

Impact to the Customer

The final robotic welding cell that MWES provided to our customer afforded them a number of benefits. Such as reduced rework, increased production throughput, decreased worker injury or downtime, and weld quality that is extremely consistent and reliable.

Midwest Engineered Systems has a wide range of experience in building robotic weld cells. If you’re looking to improve your welding automation throughput, we have the knowledge and experience to make the project a success.

Contact us to learn how Midwest Engineered Systems can automate even your most complex and challenging operations today!

Innovation Through Automation

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