The welding quality of the solid steel parts are consistent and corresponds to Crown’s high standards. The production interruptions for setting up and teaching new components has also been reduced to a minimum. parallel to the productive operation of the system) and as a result the downtimes of the system have been significantly reduced. This is because the programming takes place in the simulation environment of FASTSUITE Edition 2 (offline, i.e. Instead of taking several days, programming a new workpiece or part variant now only takes a few hours. The result: The first welding cells were integrated into the simulation environment at the beginning of summer 2017. At the customer’s site, phase 3 began with the calibration of the facility with the digital model. This was followed by the creation of a digital layout model of the cell (phase 2) that corresponds to the real installation. At startup, CENIT configured the software for the requirements of the corresponding system (phase 1). The implementation project had three phases. FASTSUITE was able to demonstrate its “ease of use” and the high level of expertise in welding production that CENIT brought gave Crown additional assurance that they had found the right partner. Although the cell had not yet been calibrated and prepared for offline programming during the test, the toolpath was already very close to the expected result on the test part. The performance of FASTSUITE in the field test was convincing to Crown. External axes and workpiece positioners are automatically positioned and interpolated.The parameters for the weld seams and the positioning of the torch to the workpiece can be easily adjusted if required.In this way, many manual programming steps are avoided and optimal process parameters are always used. Welding path generation not only describes the robot's motion paths, but also includes the control commands for the welding technology. CAD data-based welding seam generation (CAD-to-path algorithms) with automatic approach and departure strategies.Above all, it was judged how well the download works and how close the robot follows the contour of the weld path. A benchmark was set to program a component with the OLP software on a Reis compact weld cell and perform a download. The 3D simulation platform offers a sophisticated technology package specifically for offline programming of welding processes. One supplier convinced the team: The IT and software consulting company CENIT, with its software FASTSUITE Edition 2, could fulfill their requirements. Florian Braun, project manager in manufacturing engineering, saw an opportunity to optimize the use of welding robots. This makes manual teaching and fixture construction difficult.įor some time, Crown has been considering using offline programming. However, some of the solid steel components have seams that are difficult to access or many welds on a small area. Programming and fixture construction play an important role. Today there are several complex robot systems with up to 13 axes in the production floor. High quality standards based on a customer-oriented focus are met by Crown’s high vertical integration: up to 85 percent of the components are produced in-house.Ĭrown has been producing forklifts in the Roding facility since 1986. For the production of forklifts, it is critical to develop robust and durable products that meet the customer’s high demands for quality, ergonomics, and reliability, as well as meeting safety-relevant requirements. As a customer-oriented innovation leader, Crown regularly sets trends in the field of material flow solutions. The US-based, family-owned company has a global production, sales, and service network with 19 manufacturing sites around the world and more than 500 sales offices in 84 countries. Crown is one of the five largest forklift manufacturers in the world.
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