TPT May 2024

ARTICLE

Fronius

our requirements in every respect. On top of that, Fronius is ready to work with us to evolve the system and adapt it to new needs.” Synonymous with efficiency At Anton Paar, new welds are programmed offline – away from the welding system – rather than directly on the system, as is often the case. Rather than stopping ongoing welding work, welding continues during programming, increasing productivity. The welding technicians create the conditions for this by importing the CAD data of the measuring device components to be welded into the Fronius Pathfinder ®. Various joining scenarios are then tested and welding sequences are defined and optimised in the course of simulations. Starting points, work angles of the welding torches, torch offsets in the corner areas and all reorientations of the welding robot are all taken into account during these simulations. Pathfinder identifies instances where the robot range is exceeded, known as axis limits. By the software operators correcting the storage location of the workpiece and positioning it within arm’s length of the welding robot, potential collisions between the torch and various component edges are avoided at an early stage. Sources of errors are identified If the track needs to be corrected, the affected teach points can be easily moved by dragging and dropping them. When the approach to the component needs to be changed, the specialists simply press “Reset.” The virtual robot then moves to the home position to start a new approach run. Under real-life conditions, operators would have to complete the time-consuming process of retracting the robot, moving it to the home position with the robot controller and restarting the teaching process. By opting for the Pathfinder offline programming and simulation software, the experts at Anton Paar not only gain valuable time for welding work but also identify sources of error ahead of time. Once a welding program has been set up in Pathfinder, it is translated by a so-called post-processor into the specific code of the Fanuc welding robot. It can then be transferred to the welding system via data transfer using a LAN connection, for example. A key feature that provides effective support for production planning as a whole is the “Determination of cycle time” function, which includes welding speeds as well as gas pre-flow and end crater filling times. Compared to teaching with the robot controller, Pathfinder can achieve a time savings of up to 90 per cent, depending on the component geometry and welding requirements. Customised for Anton Paar Anton Paar has access to custom workflows for welding its many different components, including the three main workflows, which are a prime example of the incredible flexibility in the range of components.

Programming welding sequences and simulation using Fronius Pathfinder

Workflow 1: the components are welded on the turn-tilt positioner. A pallet loaded with components is removed from the pallet rack and temporarily stored on a pallet storage table. The handling robot then attaches a suitable gripper for picking up components with six different ones being kept in what is known as a gripper station. Equipped with the gripper, the handling robot picks up the components and fixes them in a component-specific clamping device, which is already installed on the manipulator. The robot always removes one component at a time, which is then joined and returned to the pallet. Workflow 2: the components are welded directly on the pallets, with the handling robot transporting the pallets from the pallet rack and positioning them in front of the welding robot. The handling and welding robots can then perform coordinated movements together during the welding process, enabling them to weld not just simple seam geometries but complex ones as well. Workflow 3: the components are removed individually, positioned by the handling robot and move in sync with the welding robot during welding. This is called “coordinated motion.” The system knows what to do In addition to the innovative Fronius welding technology, controls, tool centre point (TCP) measurement, torch cleaning station and enclosure, the robotic welding system consists of seven core modules that collaborate on the basis of software control. These consist of a handling robot, a welding robot, a turn-tilt positioner with forming gas unit, a pallet store with two racks, a gripper station, a torch changing system and a pallet repository inside the system. The following steps are required in order for those modules to interact precisely during the working cycles. First, pallets and components are created together in the HMI-T21 RS system controls, which are provided with four important pieces of information by the relevant welding specialist: (1) the pallet type and (2) the type (3) the number and (4) the position of the components on the pallet – for example, how many main carriers or oscillator housings are located in which position on which pallet. If it is an offset pallet, the component position is calculated on the basis of the so-called offset distances between the components, with the first component assuming the master position.

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MAY 2024