In July 2022, the Ministry of Human Resources and Social Security released the second quarter of the "National Recruitment of the 100 Most Shortage of Jobs" Ranking", and "welders" were on the list, ranking 15th.
As a type of work with high technical requirements and certain health risks, the "demand" is greater than the "supply", which is not only reflected in the difficulty of recruitment, but also in the difficulty of employment. On the one hand, because of the repetitive and boring characteristics of factory work, the stability of young workers is generally weak, and because of the limited technical level of the initial entry, the quality of manufactured products will be affected to a certain extent. On the other hand, the high salary of a highly qualified welding technician is hard to find, so the more experienced the technician in the manufacturing enterprise, the higher the workload, which indirectly affects the efficiency of the completion of production tasks and the guarantee of product delivery. In addition, welders generally have limited ability to grasp emerging production technologies, although many enterprises have introduced automation equipment, its penetration rate is also challenging, and many manufacturing companies even need to hire a special person to take care of the automation equipment with higher operational requirements. The multiple problems faced by the "young and old" have put many enterprises in a dilemma.
Universal Robots cobots offer a wide range of automated welding solutions
Acutely aware of this industry-wide challenge, Universal Robots (URs) continues to offer a wide range of automated welding solutions, including mobile welding stations that can be adapted to welding process packages for different welding machine brands, such as multi-layer multi-pass welding, weld seam positioning, and more. This includes the TruArc Weld 1000 collaborative welding workstation, developed in collaboration with TRUMPF (China) Co., Ltd. (TRUMPF China), a global company in industrial machine tools, laser technology and electronics. Equipped with the UR10e collaborative robot, this solution focuses on automating "multi-mix, low-batch" welding tasks, increasing production capacity, releasing manpower, stabilizing product quality, optimizing the welding working environment, and promoting business transformation for manufacturing enterprises.
Collaborative robots: the best "hand replacement" for welding technicians
Compared with industrial robots, which are more complicated to program, operate and maintain, in terms of application, collaborative robots can greatly improve the challenges faced by traditional manual welding in terms of safety and stability, ease of operation, quality controllability, and floor space advantages.
· Stable human-machine collaboration to protect skilled workers: Universal Robots' technology ensures that cobots limit their force when they come into contact with workers. The user can also program the Universal Robots to activate a deceleration mode when a person enters the cobot's work area and resume full speed operation when the person leaves.
The · system is simple and easy to use, increasing the popularity of automation equipment: Universal Robots provides a simple graphical programming method, and the dragging and teaching function allows ordinary operators to complete welding tasks independently, without the need for professional programming skills, reducing labor costs.
· Welding quality is controllable, creating better benefits for enterprises: robot operation is more accurate and controllable than manual operation. Universal Robots cobots can handle many types of welding, such as TIG, MIG, spot, arc, ultrasonic and plasma welding, enabling flexible, efficient and free welding processes with reduced production downtime and material waste. In the case of the UR10e cobot, for example, the range of action is 1300 mm, and the repeatability is +/- 0.05 mm.
In addition, the small footprint of the Universal Robots cobot allows it to be installed at any angle and has 17 configurable safety features, so there is no need for safety fences, making full use of the space in existing production lines and plants, and reducing the overall implementation cost of the project. Globally, Universal Robots has successfully automated welding for a large number of customers, including three local metalworking manufacturers that have partnered with TRUMPF China – TRUMPF Sheet Metal Products (Taicang) Co., Ltd. (TRUMPF Metal), Ningbo Chenyu Machinery Technology Co., Ltd. (Ningbo Chenyu) and Zhejiang Haichuang Manufacturing Technology Co., Ltd. (Zhejiang Haichuang). All three companies are currently deploying TruArc Weld 1000.
Human-robot collaborative welding workstation: a productized intelligent solution
TruArc Weld 1000 Collaborative Welding Workstation
The TruArc Weld 1000 is a fully equipped machine equipped with the UR10e cobot and designed with safety features such as a vacuum cleaner and anti-glare grille that can be quickly used by the user with video tutorials. This solution is suitable for a wide range of sheet metal welding jobs, including common carbon steel, stainless steel, galvanized sheet, aluminum alloy welding, and 1-3mm sheet welding, with CMT cold metal transition technology.
· The technology industry has a specialty, aiming at solving the "multi-variety, small batch" welding task: in the production state of "multi-variety, small batch", the biggest bottleneck of automatic welding equipment is the cumbersome pre-welding preparation programming teaching and parameter debugging. The TruArc Weld 1000 system is highly integrated, allows for fast programming, and is truly ready to use right out of the box and is an automated welding cell that can be quickly put into production.
· Get started, technical novices are no longer afraid of automation equipment: TruArc Weld 1000 is simple to program, using drag-and-drop, modular task mode, whether it is a young skilled worker or a senior welding master, can quickly learn to use the process after simple training, completely changing the operation threshold of traditional industrial robot programming.
· Dual-station design, multi-task parallelism maximizes productivity: The TruArc Weld 1000 allows for quick switching between single/dual station working modes. Depending on the component and batch size, the welding cell can be used in single or double station operation. For example, welders can process larger batches of small parts or one large part at the same time during production.
"As a subsidiary of the TRUMPF Group, we were one of the first customers to experience the TruArc Weld 1000, and the automated welding ideas of this machine were very different from the other options we had visited at the time," said Cai Hongjia, Production Manager of Trumpf Sheet Metal Products (Taicang) Co., Ltd. TruArc is a combination of robots and welding machines that are productized for automated welding, rather than simply integrated. The TruArc's human-machine interaction, user interface, and parameter settings are so smooth that our welders can get up to speed quickly and no professional background is required. The deployment of TruArc has exceeded our expectations for more than a year, and has opened up our imagination of the future of intelligent welding equipment, which not only reduces the labor load of workers, but also extends and expands the scope of TRUMPF metal sheet metal processing business. ”
Xu Yulun, Deputy General Manager of Ningbo Chenyu Machinery Technology Co., Ltd., said: "Before choosing TruArc, we visited other brands and also researched traditional industrial robot solutions. The biggest advantage of TruArc is its system, TruArc is simpler to operate, the overall operation is smoother, the requirements for operators are lower, and the time cost is lower. After a year of use, its programming convenience and overall welding effect can meet our expectations. After the deployment of TruArc products, our production mode has gradually moved from simple blanking and bending to complete sets, and TruArc gives us the confidence to receive more demanding processing orders, and we believe that our demand for intelligent equipment will also increase in the future. ”
Liu Dahai, Chairman of Zhejiang Haichuang Manufacturing Technology Co., Ltd., said: "After more than a year of deployment, after many production processes, TruArc can indeed solve the problems we face in production and bring us real convenience. If TruArc is able to add additional features to the device in the future, we will invest more in this device in the future. ”
Automated welding technology: significantly increase production capacity, and have broad application prospects
Since the deployment of automated welding technology, the production efficiency, product quality and business scope of the above three companies have been significantly improved, which is reflected in:
· Programming teaching time reduced by 50% [ Data source: Zhejiang Haichuang, one year of practical feedback, depending on the complexity of the workpiece. September 2022]: Compared with traditional industrial robots, the human-robot collaborative welding workstation is easy to program, saving nearly 50% of the time investment, and can be quickly deployed and put into production.
· Welding production efficiency increased by three times [ Data source: Zhejiang Haichuang, processing site data of specific batches of welding products, September 2022]: In the case of the same small welding products, manual welding is completed 100 pieces per day, using TruArc Weld 1000, the number of welding parts per day can be 300 pieces, the production capacity is greatly increased by nearly three times, and the product delivery period is more guaranteed.
· Stable delivery quality: Thanks to the precise action of the collaborative robot, the quality of welding products has been greatly improved, which is more uniform and stable than manual operation, and the product quality is stable and guaranteed.
· Production capacity improvement, business expansion: With the improvement of production efficiency, delivery time and delivery quality, the three enterprises have greater confidence in undertaking products with higher precision requirements, and gradually transform from the traditional blanking and bending processing format to undertake more comprehensive metal processing tasks, which greatly broadens the business breadth of the enterprise.
Human-robot collaborative welding workstation is one of the applications of welding automation technology, and Universal Robots will continue to develop new welding automation technology, continuously broaden the application scene, and help more local manufacturing enterprises facing actual production problems to carry out welding automation transformation, and gain a broader development space and competitive advantage.
About Universal Robots
Universal Robots is committed to reinventing the way the world works with its best-in-class robotics platform.
Since the launch of the first commercial cobot in 2008, Universal Robots has developed a portfolio of products for different working radii and payloads, including UR3e, UR5e, UR10e, UR16e and UR20.
Each model works seamlessly with the UR+ ecosystem's rich suite of end-effectors, software, accessories, and applications, making it suitable for a wide range of industries and easily adaptable for different tasks.
Universal Robots, part of Teradyne, is headquartered in Odense, Denmark, and has offices in markets such as United States, Germany, France, Spain, Italy, Czech Republic, Romania, Turkey, China, India, Japan, Korea, Singapore and Mexico.
Universal Robots has sold more than 50,000 cobots worldwide.
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