Welding Automation & Rovotics

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ESABs Friction Stir Welding robot Rosio™ enables flexible joining of complex structures, preferably in Aluminium. The ability to perform welds in an arbitrary direction of a 3-dimensional workspace increases the possibilities of usage for new challenging FSW applications.

The cell consists of an ABB IRB 7600 robot, modified for the purpose of FSW. The welding equipment is integrated in the mechanical structure of the robot without limiting the robot’s standard working envelope.

The robot’s reachable workspace spans over 2.5 meters, in which a down force of up to 13 kN may be applied during welding. Running on the state-of-the-art control system IRC5, an embedded force control solution allows in-contact motions with high accuracy.

Provided with the system is an extension to the standard motion programming language. This extension includes instructions for welding linear in arbitrary directions, circular and square shaped paths, as well as functionalities to support custom made path programming and spindle operations. This to enable welding with minimum efforts. To provide valuable feedback to the operator, a man-machine-interface is included. Extending the IRC5’s own interface on the Flex Pendant, based on WinCE.

• Designed for complex joints
• The latest IRC5 control system, featuring embedded force control, ensures high accuracy in-contact motion
• The upgraded motion software permits linear welding in arbitrary patterns, as well as circular and square paths
• Additional functionalities to support customized path programming and spindle operation, permit advanced welding, even with limited programming skills
• A user-friendly HMI extends the IRC5 interface, providing full operator feedback via a Flex Pendant

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Development within the field of robotic welding equipment moves rapidly. New materials and processes are constantly being introduced and all demand new functionalities and programs to meet their performance needs. By upgrading your robot installation with new welding equipment you can substantially increase productivity.

Based on the Aristo® Mig 5000i CAN-Bus controlled power source ESAB has a standard modular solution for upgrading your welding equipment - the Aristo® robot package I/O Universal. This modular solution is a complete system that can be mounted on robot installations or used for mechanized solutions. The Aristo® Retrofil I/O Universal is used together with the Aristo® U82 Plus I/O which ensures a good man-machine communication and gives you quick and easy access to all the relevant parameters and synergic lines.

ESAB provides several robot package solutions ranging from the simple and low cost to high tech, with offerings for both analogue or digital communication with external systems.

• New materials require modern welding processes and functionalities all of which are included in today's equipment
• Easier programming and increased capacity to store welding parameters enables fast settings
• Ensured availability of spare and wear parts
• The introduction of ESAB Marathon Pac™ and Endless Pac™ filler metals

 

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ESAB’s LEGIO™ platform is developed to provide a standardized and modular approach to FSW utilization. LEGIO™ is designed with a rigid framework for high performance during high-load conditions with a working range (welding head travel) from 1 and 5 meters. It comprises heavy-duty bearings and the welding head travel is actuated using a ball-screw system.

The welding head is hydraulically actuated, which allows the high FSW forces to be applied minimizing the space required. The contact force conditions is controlled by the PLC, which provides a dedicated close-loop controller for this vital process parameter.

The spindle is driven by an AC-motor, which provides the torque and spindle rotation needed for the intended applications. Liquid cooling is provided to minimize the wear on the spindle components and the pin tool.

All LEGIO™ machines are controlled using the latest of PLC technology and high accuracy drives. This allows the machine’s axis position and speed to be controlled delicately and precise.The Z-axis control works in either on position or on set force control mode.

The menu driven 15” touch-screen HMI interface is designed specifically for FSW. It is the interface for setting up the process parameters, the welding path as well as the most common machine parameters. It also provides monitoring capabilities of the process parameters, alarms and system status.

• The LEGIO™ platform is available in three models; ST, U, and UT
• The ST-model is designed for linear welding
• The U- and UT-models for 2-D welding Y-axis range 15.7 in.
• All models can be equiped with three different type of FSW Head sizes 3, 4 and 5
• Other sizes and combinations can be quoted on request

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For use with flux handling systems

• Designed for use with any flux handling system
• The system is based on the absorption principle - reduces the risk of hydrogen cracking in weld metal by ensuring flux remains dry
• Built-in monitor - warns if the programmed humidity limit is exceeded.

  Reduces condensation - less corrosion and malfunctions

• Simple system monitoring - manometer on pressurized dryer bottles with easy-to read dew point indicator