PROJECT SPOTLIGHT

Robotic Multi Vane Rotor Assembly Welding

Project summary

MWES integrated a robotic welding cell to manufacture multiple varieties of rotor vane configurations for use in rotary airlock valve assemblies.

The Challenge

Running an assembly process that requires any amount of welding can be difficult to staff as trained welders are hard to come by and command higher salaries for their skills. In such a process, a shortage of welders in the headcount can negatively impact overall assembly throughput and create work stoppages. To help keep throughput consistent, an industrial equipment manufacturer approached MWES to integrate an automated robotic welding cell as part of a larger assembly line. The automation system had to be run by a single operator with minimal training and it had to handle multiple part types and configurations.

The Solution

The robotic welding cell MWES integrated for this customer utilizes an ABB positioner and two ABB robots to perform the welding in tandem while a third ABB robot handles positioning the blades on the shaft. The cell utilizes standard safety features, including fencing with mesh safety guarding and light curtains at the entrance. The operator’s responsibilities simply involve loading the blades and the shaft into the fixturing and selecting the part program to run on the HMI. 

The welding system handles shafts that are 14-50 inches long and blades with a max size of 24×9 inches. The operator loads the 6 or 8 blades and a shaft into fixturing on one side of the positioner as parts are automatically handled and welded on the guarded side of the positioner. Once the part being welded is complete, the new part loading process is completed, and the front area of the cell is cleared, the positioner will automatically rotate to allow for automatic welding. The finished part is then removed by the operator and new parts are loaded into the fixturing.

Impact to the Customer

This robotic welding automation system MWES provided our customer allowed them a way to easily and safely manufacture over a dozen part configurations while only utilizing a single system operator. This welding cell rapidly produces parts that are consistent and free of defects, affording our customer a long-term solution for their valve manufacturing.

Midwest Engineered Systems has extensive experience integrating robotic welding systems. If you want to improve your welding manufacturing throughput, we have the knowledge and experience to make the project successful.

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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