INSUBCONTINENT EXCLUSIVE:
Figure 1: The fully automated robotic welding work cell, with all actions managed by an AutomationDirect Productivity PLC, synchronizes the
welding process, robotic motions, and component positioning
Source: Properly WorksWhen a business known for its expertise in welding and steel fabrication protected a contract to supply fencing for
building of a bridge, there was no time at all to lose
Faced with the overwhelming job of producing over 3 miles of fencing within 90 weeks, it turned to Properly Works, a systems integrator with
a tested record of enhancing production operations with automation and robotics, to help develop a service that would not only decrease the
general project timeline, but likewise yield high-quality results.A typical section of bridge fencing includes 16 steel pickets protected
When done by hand, each sector required roughly 10 hours for setup and welding.With years of experience as a market leader in commercial
welding and steel fabrication jobs such as this, Lancaster, N.Y.-based Seibel Modern knew that an essential to success would be making the
Recognizing the advantage automation would bring to this laborious procedure, work started to make use of a collective welding robot and
establish an automatic component to increase efficiency.Implementing a tabletop-type robotic arm with a welder was the initial strategy,
however it was quickly identified that more considerable automation would be needed
Elma Center, N.Y.-based Properly Works approached the project by working together with the fence producer to incorporate formerly
independent systems into a completely automated robotic work cell (Figure 1)
The difference was undeniable—-- an amazing 12-1 reduction in time, with the included benefit of minimizing touch up work by 50%
To better value the successful results, we’& rsquo; ll take a closer take a look at the approach that made it possible.Collaborators
bridge understanding gapsWith the clock ticking, this would be a collaborative task
Properly Works and Seibel Modern worked to develop a specification, with Seibel defining the welding geometry and requirements and the
fixturing, while Properly Works applied sensors and automation for optimal operation and safety.Drawing on its metalworking competence,
Seibel Modern produced the welding component powered by Properly Works’ & rsquo; servo motor driven rack-and-pinion mechanism to position
The fixture included clamping and horizontal-to-vertical positioning utilizing a hydraulic lift.Synchronization of motion with the gantry
positioning system for the robotic welding arm was a core requirement to the design.Welding task requires orchestrated productionPutting the
pieces of each independent system together needed a thoughtful combination technique
The innovative digital welder required to communicate not just with the smart robot, however also the systems controlling the welding
component, the workcell safety systems, and the operator controls.The style likewise needed the versatility to adjust to various fence
A programmable logic controller (PLC) was figured out to be the ideal genius for the application, managing the movements of each control
subsystem.As an independent systems integrator (SI), Properly Works releases these systems using a variety of brands for robotics, welders,
motion control systems, and basic commercial automation products.When there are no preliminary defined requirements driving the work,
Properly Works normally chooses selecting AutomationDirect‘& lsquo; s portfolio for automation and motion control due to the detailed
variety of items, ease of choice, usage, and support, and the exceptional price/performance ratio.Figure 2: An AutomationDirect Productivity
3000 PLC provided the programming, memory, and interactions capabilities to manage the SureServo2 drive with the robotic welder and other
Source: Properly WorksFor this project, the AutomationDirect Productivity 3000 PLC was picked as the controller for the robotic work cell
for its adaptability and scalability (Figure 2)
A plethora of functions and functionality, integrated with large storage capability and EtherNet/IP communications all factored into this
This PLC would coordinate movement through an AutomationDirect SureServo2 system.With hardwired input/output (I/O) signals, as well as
IO-Link linked discrete signals, and Ethernet and serial digital interactions, the PLC quickly interfaced with all robotic functions, the
digital-based welder, safety systems, the hydraulically operated welding fixture, and the motion-controlled gantry system for positioning
the robotic arm.The SureServo2 drives a pinion gear which moves the gantry rack, and the Productivity PLC has the processing power and
native movement control operates to command accurate motion while flawlessly incorporating and coordinating with the automation and robotic
components.The PLC also engages with an AutomationDirect C-more human-machine user interface (HMI), for complete visualization of the
system.Within any robotic work cell, security is paramount
Although the Productivity PLC does not have native safety-rated functions, it interfaces with dedicated security elements that are hardwired
to develop a work cell safety circuit.Several security products were used in the style including Dold security relays for keeping track of
the safety circuit, Datasensing safety light curtains (Category 4, Type 4) to find invasion into limited areas, and both mushroom pushbutton
and cable-pull safety switches emergency situation stop (e-stop) devices.The cable television pull can be set off from any place along the
cable length, supplying a hassle-free precaution inside the work cell where an e-stop button may not be within reach.To ensure the quality
of the ended up product, accurate positioning of both the robotic and steel pickets is vital for each fence section
During the welding process, the SureServo2 system manages a rack-and-pinion linear actuator to properly position the robotic throughout 9 ft
of linear travel.The PLC manages the robot’& rsquo; s position along the linear gain access to, along with 6 additional axes of motion on
board the robotic arm itself
The start and stop points for each weld are figured out by the PLC, utilizing feedback from the SureServo2 system and servo encoder sensor
Software limitations are imposed to protect against over travel.Now accepting session submissions!Special cases spark creativityAlthough a
vast bulk of the fence segments were standardized, it was periodically needed to build and bond unique segments, for instance a partial
sector with half the number of pickets
The PLC made it simple for Properly Works to develop a program able to accommodate variations in fence segments.For each special case, a
“& ldquo; recipe & rdquo; alternative was developed within the programs reasoning
Similar to how recipes are used at the same time industry, utilizing a dish technique made it simple for the operator to dynamically
configure the size and type of each fence segment.To preserve consistent, premium welds throughout the process, the system was designed to
attend to the impacts of splatter from arcs and sparks on the welding nozzle by using an automated reamer to occasionally clean debris from
the welding nozzle.In this application, it was more efficient to start the cleaning function timing and sequence straight from the PLC
This enables the PLC to send the robot to the cleaning station at the most hassle-free times during the procedure after a specific number of
welds are completed, optimizing performance while reducing weld defects and saving consumables.The voltages and currents used during welding
operations cause the existence of high electromagnetic interference (EMI) and radio frequency interference (RFI)
To make sure reliability in this harsh EMI/RFI environment, protected cable televisions and accessories like EMC cable clips, were used to
safeguard the electronic equipment in the workcell.Welding on the (graphical) fenceOne of the notable functions of the system is the
intuitive operator interface
Constructed on the C-more HMI panel, the color touchscreen user interface is effective yet easy to use
The HMI includes a visual representation of each fence sector (Figure 3), highlighting the position of each weld.The welder has digital
fault detection, efficient in noticing process conditions that will cause a weld problem such as incorrect present or voltage, absence of
gas, or the end of a wire coil
When a procedure abnormality is spotted, the system will flag the weld
This is visible on the HMI and makes it easy for the operator to return the system to the home position and reinitiate the weld.The operator
also has the capability to flag any weld through the HMI while they are observing the procedure
In addition, the welder can pick specific fence posts, or even particular welds, to either consist of in the welding procedure, or leave out
This allows operators to do rework as needed after inspection.Figure 3: The C-more HMI shows each weld, with a flagging system to easily
mark and identify process problems, enhancing performance, streamlining rework, and increasing general quality
Source: Properly WorksClient sees substantial, quantifiable resultsThe client was impressed with how simple the system was to run, and it
discovered that any flooring staff member might successfully run the devices after very little training
With the brand-new automatic system, a single fence sector might be produced in 45 minutes —-- an unbelievable enhancement from the
initial 12 hours!Furthermore, weld defects were decreased, reducing the need for touchup work by more than 50%
With shown results from the initial workcell, the whole operation was expanded to a total of 3 systems to increase throughput and maximize
operations.With the tight task timeline, Properly Works turned to AutomationDirect for many job automation needs consisting of the PLC, HMI,
servo system, electrical items, and security elements
The website provides stocking openness, so it was simple to select and directly acquire products that fit the technical requirements and
timeline without the additional trouble of getting quotes for numerous products through several distributors.Both technical efficiency and
business elements have raised AutomationDirect to be the preferred supplier for Properly Works.Based on this project exceeding all
objectives, the customer is now excited to pursue extra automation jobs with Properly Works
With the best integration partner and smart innovation, even the most difficult production difficulties can be overcome with speed and
precision.About the authorDominic Myers is the president of Properly Works, leading a cross-functional team supplying automation solutions
for basic manufacturing and food production
He has more than 25 years of experience in organization method, item advancement, and market expansion, and a proven track record of
providing innovative, lucrative services throughout diverse industries.Myers is on the Industry board of advisers at Buffalo State College,
and the board of directors at the Buffalo Niagara Manufacturing Alliance (BNMA)
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