The manufacturing industry is perennially faced with the dilemma of difficulty in recruiting welders, and compared with indoor welding tasks, outdoor building welding faces more prominent human resource challenges due to complex environment and engineering characteristics.
In outdoor engineering, due to the high building height and seismic performance design, additional requirements are put forward for welding quality. At the same time, the building often involves a large number of complex structures such as truss columns, main trusses, secondary structures, etc., the node structure is complex, the welded joint forms are many, and the welds are criss-crossed, resulting in great technical difficulty, all of which put forward extremely high requirements for the stability of outdoor welding quality. In traditional manual welding, young workers who are just starting out in the industry have limited skills, and even skilled welders are challenged to maintain high quality consistently under high loads and tight construction deadlines. In this context, collaborative robot welding has increasingly become an important means to solve the problem of outdoor welding employment due to its advantages of automation, high flexibility and easy programming.
Universal Robots (UR) is keenly aware of how cobots can help overcome common challenges in the welding industry, and continues to offer a wide range of automated welding solutions, successfully helping a large number of customers automate welding worldwide. In the field of outdoor construction welding, Universal Robots has partnered with technology partner SquareDog Robotics (SQD) to bring the collaborative welding robot SQD-Robo Welder to outdoor construction sites.
Equipped with Universal Robots' UR10 collaborative robot, this solution has been used in many key projects such as Taikoo Shing Phase 2 in Hong Kong, Wong Chuk Hang MTR Station, Kai Tak Development Area New Emergency Hospital, Hong Kong International Airport Three-runway System Project, and Kwong Wah Hospital Redevelopment Project. Taking the Kai Tak construction site as an example, there are currently 10 welding robots working on the site, using innovative technology to solve the manpower problem and efficiently promote the construction progress. The operator himself does not need to hold the qualification of medium or large welding process level, and there is no need for a full-time worker, and the robot can be quickly put into work.
【Taikoo Shing Phase 2, Hong Kong】 【Guanghua Hospital Reconstruction Project】 【Hong Kong International Airport Three-runway System Project】 【Kai Tak Development Area New Acute Hospital】
SQD specializes in construction welding automation, which is combined with Universal Robots' cobots to form collaborative welding robots. The Adaptive Robotic Control (ARC) system in SQD's core technology Robota6th allows any worker to easily and intuitively complete the setup of industrial robots in 2 to 5 minutes, which is a new breakthrough in automation in the construction and welding industry. At the same time, its "UR + Welding" interactive welding system can calculate the optimal automatic calculation path based on the scan data obtained by the laser sensor, improving process stability and operational flexibility. Specifically, collaborative welding robots can help customers overcome the challenges of traditional manual welding in the following aspects.
● Ensure stable and consistent welding quality: In traditional welding, the welding quality is determined by the skills and experience of the welder, and there is a general shortage of skilled welders. The use of collaborative robots to perform welding tasks is more accurate and controllable than manual operation, and even technical novices can ensure stable and consistent welding quality.
● The system is simple, ordinary workers can quickly get started: Universal Robots provides a simple graphical programming method, dragging the teaching function, ordinary operators can complete welding tasks independently, without professional programming skills. What used to take workers three years to become a skilled welder now takes only two weeks to get an operator's license, get up and running immediately, and program the robot in minutes.
[Simple system, easy to operate]
● Easy deployment, parallel tasks, and flexible task switching: Universal Robots cobots have a small footprint, can be installed at any angle, and have 17 configurable safety functions, so there is no need to set up a separate isolation space, and the deployment is more flexible than traditional robots; Different from the traditional manual welding mode in which one worker can only complete one job, the SQD-Robo Welder allows one operator to control two robots at the same time, and the parallel dual tasks further improve flexibility and productivity. In addition, the SQD-Robo Welder can be installed on a specific device and work in different environments and positions using the ARC mode, such as I-Tsubaki welding and other intelligent welding without pre-programmes.
[Two SQD-Robo Welder adaptive welding robots perform I-Tsubaki welding at the same time]
● Multi-pronged approach to protect the safety of skilled workers: The use of cobots can help reduce the risks of burns, electric shock, visual impairment, and inhalation of harmful gases that workers often face during manual welding tasks in the past. Universal Robots' patented technology also ensures that the cobot limits its force when it comes into contact with a worker. The user can also program the Universal Robots to slow down when a person enters the cobot's work area and resume full speed when the person leaves.
● Cost reduction and efficiency increase: Customers using SQD-Robo Welder collaborative welding robots have an average productivity increase of 25%, cost savings of up to 40%, and a payback period of less than 3 years.
"We have always been committed to helping the construction industry improve the efficiency and quality of welding projects through automation, and we are pleased to be able to combine UR cobot technology with Universal Robots to help welders better cope with complex environments and ensure more stable welding quality in outdoor construction welding," said SquareDog Robotics. From a technical point of view, we and our end customers were impressed by the technical maturity and stability of Universal Robots. From a deployment point of view, we didn't need to build an expensive automated production cell specifically for Universal Robots, and the robots were waterproof and dustproof enough to handle most outdoor work environments, making them very flexible. ”
Outdoor construction welding is one of the application areas of welding automation technology. With multiple types of welding processing capabilities such as TIG welding, MIG welding, spot welding, arc welding, ultrasonic welding and plasma welding, Universal Robots will continue to develop new welding automation technologies and expand application scenarios to help users in more fields achieve welding automation transformation.
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