Automatic cabinet panel welding line

TEL: 0086-0571-82685351

Description

Automatic cabinet panel welding line

This cabinet panel welding line adopts Joint operation of robots to achieve Fully Automatic Welding Production Line.

work piece material: cold rolled steel SPCC
work piece specifications
I:side panel size range
A. Height: 1600～2500mm
B. Width: 600～1200mm
II.left front door, right front door size compatible range
A. Height: 1600～2500mm
B. Width: 300～600mm
III.back door panel size compatible range
A.Height: 1600～2500mm
B.Width:600～1200mm
work piece precision requirements
I.The length of the the reinforcing rib on the side guard panel shall be 4 mm smaller than the inner width of the side guard panel, and the tolerance shall be negative.
II.The flatness of the welding plane of the hinge and the lock bar positioning block shall not exceed 0.1 mm.
III.The welding plane burr height of the rib, hinge and lock bar positioning block shall not exceed 0.1mm
IV.The flatness of the side panel, all door panels and the rib shall not exceed 0.1mm/50cm2
Function requirements
V.Cycle time requirement: 2min/piece. Production line utilization rate of 90%
VI.The production line requires a high degree of automation. Except for the material handling personnel, the operator must not exceed one person.
VII.feeding mode
A.Side panel, left front panel, right front panel and back door panel all automatic feeding by AGV.
B.Manual feeding the rest of material.
VIII.The design of the logistics rack should consider minimizing scratching on the surface of the workpiece, and consider the versatility for handling different parts. The storage capacity of the logistics rack is 2 hours, that is, feeding every 2 hours.
IX.Discharging mode: conveyor

Automatic cabinet panel welding line process and cycle time analysis

OP10 side panel and back door panel welding station.
Side panel welding process flow: The side panel is placed on the rack by AGV. The reinforcing ribs are assembled into an I-shaped shape at the assembly station by manual sorting. The transfer robot is equipped with a face and back double-side tooling. The face side tooling is double-layered and can realize grabbing job for the rib and side panel at the same time and place them on the single-axis positioner at the side of the 2-work-position turntable no. 1. After positioning and clamping, the turntable rotates and transfer the workpiece into the welding room. The welding robot configures the laser to complete the welding work. After the welding is completed, the turntable rotates and transfers the workpiece out of the welding room. And the welded side panel is grabbed by the two-axis truss and placed on the roller conveyor and sent out of the welding station.
Back door welding process flow: The back door panel is placed on the rack by AGV, and grabbed by the face side tooling of the transporting robot to the single-axis positioner by the side of the 2-work-position turntable no.2. The hinge hinge and the positioning block are fed to designated position through the vibrating plate. Two-axis truss carries the four-axis SCARA robot to position to grab and place the parts on the temporary storage trays one by one. The two-axis truss carries the four-axis SCARA robot and the temporary storage tray to the single-axis positioner by the side of the 2-work-position turntable. The 4-axis SCARA robot places the parts to position one by one from the temporary storage tray. After positioning and clamping, the turntable rotates the workpiece into the welding room. The welding robot configures the laser to complete the welding work. After the welding is completed, the turntable rotates the workpiece out of the welding room. The transporting robot transports the welding back door panel finished product to stud welding position. After the stud welding is completed, the welded workpiece is placed on the roller conveyor and sent out of the welding station.
OP20 left front door & right front door welding position
The left front door and the right front door uses two similar welding stations. The left front left door is placed on the rack by AGV, and is grabbed by face handling of the transportation robot to single-axis positioner by the side of a 2-postion turn table. The hinge hinge and positioning block are fed to the specified position through the vibrating plate. The two-axis truss carries the four-axis SCARA robot into position, and the parts are grabbed and placed on the temporary storage tray one by one. The two-axis truss carries the four-axis SCARA robot and the temporary storage tray to the single-axis positioner by the side of the 2-position turntable, and the four-axis SCARA robot puts the parts to place one by one from the temporary storage tray. After positioning and clamping, the turntable rotates the workpiece into the welding room. The welding robot configures the laser to complete the welding work. After the welding is completed, the turntable rotates the workpiece out of the welding room, and the welding robot grabs the welded door and place it to the stud welding station, and after the stud welding is completed, the welded workpiece is placed on the roller conveyor and moved out of the welding station.
Laser process testing station
The welding station of the laser process testing station is independent of the main welding room. It is a two-layer structure, the upper layer is used to place the laser, the chiller and the voltage regulator, the lower layer is the welding room. The KUKA welding robot is equipped with the laser welding system, and coordinates with a 2-axis positioner. The positioner is equipped with standard octagonal pore welding platform, and integrated rapid manual tooling.
cycle time analysis
Cycle time design requirement: 2min/piece

Automatic cabinet panel welding line general solution

Automatic cabinet panel welding line equipment laout	Automatic cabinet panel welding line 3D schematic

OP10 side panel and back door panel welding station

1.layout
This welding station system comprises two side panel racks, two back door panel racks, one rib loading unit, one set of transportation robot loading and unloading system, one set of hinge and positioning block loading system, one set of side panel and back door welding system, one set of automatic stud welding system, one set of conveyor line system, one set of safety fences and one set of electrical systems, the layout is shown as below:

Automatic cabinet panel welding line
Side panel and back door panel welding station schematic

2.Rack
The side panel and the back door panel are stacked structure, each workpiece is separated. There is no direct contact between the upper and lower layers. Total 25 layers. The reinforcing ribs are directly stacked on the rack, no need to worry about scratching.
The side panel and the back door are each configured with two racks for to be used in turn. The feeding method of the panel material rack is AGV feeding, and the feeding method of the reinforcing material rack is manual sorting.
3.reinforcing rib loading unit
The reinforcing ribs are manually sorted and assembled into an I-shape. Then the rib assembly is pushed into position by the cylinder to drive the slide rails, and then wait for the transporting robot to handle further. The assembly tooling is compatible with all product specifications, only requires manual adjustment when changing the specifications.

reinforcing rib loading unit

4. transporting robot loading and unloading system
Transporting robot: KUKA KR150 R3100 prime.
The transporting robot is equipped with a face and back double-sided tooling structure. Tooling on one of the side has 2 layers and can simultaneously complete the loading of the ribs which are manually placed in position, the loading of the side panel, as well as the back door panel loading. The tooling on the other side handles the unloading of finished back door panel. The tool is built with octagonal tubes and is compatible with all product specifications. Manual handling required for changing different specifications.
The transporting robot is equipped with an external shaft slide rail to realize the picking and discharging action of between different work positions. The effective stroke is 6500mm, the running speed can reach 60m/min, and the running precision is ±0.15mm (any position).

KUKA KR150 R3100 prime

5. hinge and positioning block loading system
Loading system includes vibrating disc, loading robot and truss.
The hinge hinge and the positioning block are fed through the vibrating disc, and are manually fed once every 2 hours, and loaded through the four-axis SCARA robot. The loading sequence is: vibrating disc vibrating discharging the part to the designated position → four-axis SCARA robot moves in place → Four-axis SCARA robot grabs the parts one by one to the temporary storage tray → the truss carries the four-axis SCARA robot and the temporary storage tray to the loading and unloading position → the four-axis SCARA robot puts the parts to position from the temporary storage tray one by one.
The truss is used to drive the four-axis robot to feed the hinge, the positioning block and unload the welded side panel. The relevant parameters are as follows:
Truss structure: column type
Number of truss axes: X, Z+Z two-axis (double Z-axis structure); one Z-axis is used to feed the back door hinge and the positioning block, and the other Z-axis is used for unloading of the finished side panel.
X axis effective stroke: 14000mm
Z axis effective stroke: 1000mm
X axis running speed: 40m/min
Z axis running speed: 30m/min
Running accuracy: ±0.15mm (any position) both X & Z axis

hinge and positioning block loading system

6.side panel and back door panel welding system
Configured with 2-positioin turntable. Turntable brand: FIBRO; model: AT1000, rotary diameter Φ5000mm. Each station is equipped with a single-axis positioner (Client–server model) for optimum angular position welding. Manual quick change of welding fixtures for different specifications. The welding robot is equipped with a KUKA robot, model number KR120 R2700 extra HA. The laser uses the TRUMPF TruDisk 6001 with a PFO 33-2 HA solder joint. The welding robot is equipped with external shaft slides. The relevant parameters are as follows: effective stroke: 8500mm, running speed: 60m/min, running accuracy requirement: ±0.15mm (any position).
The outer part of the welding station is a steel plate type safety room. It is modular and can be installed quickly and easily. The working room is made of double-layer steel plate with a thickness of >1.0mm. The seal between the turntable and the safety room rotation is made of a opaque flexible strip. There is an active safety fence around the welding fixture to prevent laser leakage. The layout of the work room considers the cable routing space where the galvanometer is left at the top or at the side, the space of the water pipeline, laser fiber routing space and the sufficient space for its minimum radius of curvature. A warning sign is attached to each dangerous place on the equipment, which complies with CE safety standards, and the mark is clear and not easy to fall off.
Two 2.4×1.2m pore welding platforms are arranged on the upper end of the welding room, and integrated rapid manual tooling.

Automatic cabinet panel welding line
side panel and back door panel welding system

7.automatic stud welding system
The back door panel is directly grabbed by the transporting robot and placed in the stud welding machine station. The studs are automatically fed. After the welding is completed, the back door panel is directly placed on the conveying line to be sent out of welding zone.

OP20 left front door / right front door welding station

1.layout
This welding station system includes two left front door panel racks, two right front door panel racks, one set of transporting robot loading and unloading system, one set of hinge and positioning block loading system, and one set of left front door right front door panels welding system, one set of automatic stud welding system, one set of conveyor line system, one set of safety fences and one set of electrical systems. Layout as below:

Automatic cabinet panel welding line
left front door / right front door welding station

2.rack
The left front panel and the right front panel are layered stacked, each workpiece is separated, and there is no direct contact between the upper and lower layers. The number of layers is 25. The left left door and the right front door panel are each configured with two racks to be used in turn (full-empty exchage), and the panels are fed by AGV.
3. transportation robot loading/unloading system
Transportation robot: KUKA robot, model KR150 R3100 prime.
The transporting robot is configured with a face and back double-sided tooling structure which allows it to load the left and right front panel and unload the finished door panel at the same time. The tooling is built with an octagonal tube and is compatible with all product specification, only need to manually adjust it for different specifications.
The transporting robot is equipped with an external shaft slide rail to realize the grabbing and placing action between the work positions. The effective stroke is 6500mm, the running speed can reach 60m/min, and the running precision is ±0.15mm (any position).

KUKA robot, model KR150 R3100 prime

4. hinge and positioning block loading sytem.
The loading system includes vibrating disc, loading robot and truss.
The hinge hinge and the positioning block are discharged through the vibrating disc which is refilled every 2 hours manually, and fed through the four-axis SCARA robot. The loading sequence is: the vibrating disc vibrates and discharges the parts to the designated position → four-axis SCARA robot moves in place → Four-axis SCARA robots grab the parts one by one to the temporary storage tray → truss drives the four-axis SCARA robot and the temporary storage tray to move to the loading and unloading station → four-axis SCARA robot puts the parts from the temporary storage tray one by one.
The truss is used to carry the four-axis robot to feed the hinge, the positioning block and unload the welded side panel. The relevant parameters are as follows:
Truss structure: column structure
Truss axis: X&Z 2 axis
X axis effective stroke: 10500mm
Z axis effective stroke: 1000mm
X axis running speed requirement: 40m/min
Z axis running speed requirement: 30m/min
Movement accuracy: X & Z axis both ±0.15mm (any position)

hinge and positioning block loading sytem.

5.side panel and back door panel welding system
Configured 2-position turntable. Turntable brand: FIBRO; model: AT1000, rotary diameter Φ5000mm.
Each station is equipped with a single-axis positioner (client/server model) for optimum position welding. Manual quick change of welding fixtures for different specifications. The welding robot is equipped with a KUKA KR120 R2700 HA robot. The laser uses the Trumpf TruDisk6001 with a PFO 33-2 HA welding head. The welding robot is equipped with external shaft sliding rail. The relevant parameters are as follows: effective stroke: 8500mm, running speed: 60m/min, running accuracy requirement: ±0.15mm (any position).
Share the same welding room with OP10.

Automatic cabinet panel side panel and back door panel welding system

6. automatic stud welding system
The back door panel is directly grabbed by the transporting robot and placed in the stud welding machine position. The screws are automatically fed. After the welding is completed, the back door panel is directly placed on the conveying line to be sent out of the welding area.

Automatic cabinet panel welding line laser process testing station

Welding robot model: KUKA KR60HA R2033, equipped with DKP400 2-axis positioner, linkage action. The standard octagonal pore welding platform and integrated manual quick change tooling are arranged on the 2-axis positioner.

KUKA KR60HA R2033

Automatic cabinet panel welding line work station main configuration list

name	description	brand	unit	quantity
1	Side panel reinforcing rib loading unit	loading unit frame	JINGGONG ROBOTICS	SET	2
		reinforcing rib positioning tooling	JINGGONG ROBOTICS	SET	1
		rod-less air cylinder	FESTO	SET	1
		guide rail L=1250mm (including sliding block)	HIWIN	SET	2
		safety fence	LOCAL	SET	1
2	Front door loading & unloading, stud welding and side panel unloading unit	loading rack	JINGGONG ROBOTICS	SET	4
		Transporting robot KR150 R3100 prime	KUKA	SET	1
		Transporting robot sliding rail 8m	JINGGONG ROBOTICS	SET	1
		Transportation robot base	JINGGONG ROBOTICS	SET	1
		Transporting tooling	JINGGONG ROBOTICS	SET	1
		Automatic stud welding system	HBS/OTHER	SET	1
		Stud welding tooling	JINGGONG ROBOTICS	SET	1
		Big door panel roller line 1(L×W：8.5×1.5m）	MODULAR/OTHER	SET	1
		Big door panel roller line 2(L×W：17×3m）	MODULAR/OTHER	SET	1
		Jacking translating mechanism	MODULAR/OTHER	SET	3
		Jacking mechanism	MODULAR/OTHER	SET	1
		Side panel roller line (L×W：5.5×1.5m）	MODULAR/OTHER	SET	2
		safety fence	LOCAL	SET	1
3	Hinge, positioning block loading and side panel unloading truss manipulator	gantry	LOCAL	SET	1
		X axis servo motor (including drive)	SIEMENS/OTHER	SET	2
		Z axis servo motor (including drive)	SIEMENS/OTHER	SET	2
		Side panel unloading tooling	JINGGONG ROBOTICS +OTHER	SET	1
		Side panel unloading roller line (L×W：2.5×0.8m）	MODULAR/OTHER	SET	2
		vibrating loading disc	BFC/OTHER	SET	2
		loading positioning mechanism	JINGGONG ROBOTICS	SET	2
		Loading robot G6 653SR	EPSON/OTHER	SET	1
		SCARA robot tooling	JINGGONG ROBOTICS +OTHER	SET	1
		Work piece placing positioning tray (5-pieces)	JINGGONG ROBOTICS	SET	1
4	Back door loading & unloading, stud welding unit	loading rack	JINGGONG ROBOTICS	SET	4
		Transporting robot KR150 R3100 prime	KUKA	SET	1
		Transporting robot sliding rail 8m	JINGGONG ROBOTICS	SET	1
		Transporting robot base	JINGGONG ROBOTICS	SET	1
		Transporting tooling	JINGGONG ROBOTICS	SET	1
		Automatic stud welding system	HBS/OTHER	SET	1
		Stud welding tooling	JINGGONG ROBOTICS	SET	1
		Unloading roller line 1 (L×W：3×1.5m）	MODULAR/OTHER	SET	1
		Unloading roller line 2(L×W：6×2.5m）	MODULAR/OTHER	SET	1
		Jacking translating mechanism	MODULAR/OTHER	SET	2
		Stairs and pedal	LOCAL	SET	2
		Safety fence	LOCAL	SET	1
5	High, positioning block loading truss manipulator	gantry	LOCAL	SET	1
		X axis servo motor (including drive)	SIEMENS/OTHER	SET	1
		Z axis servo motor	SIEMENS/OTHER	SET	1
		Vibrating loading disc	BFC/OTHER	SET	2
		Loading positioning mechanism	JINGGONG ROBOTICS	SET	2
		Loading robot G6 653SR	EPSON/OTHER	SET	1
		SCARA robot tooling	JINGGONG ROBOTICS+OTHER	SET	1
		Work piece placing positioning tray (8-piece)	JINGGONG ROBOTICS	SET	1
6	Top and bottom panel fetching unit	Loading rack	JINGGONG ROBOTICS	SET	4
		Loading robot KR120 R3200 PA	KUKA	SET	1
		Transporting robot sliding rail 10m	JINGGONG ROBOTICS	SET	1
		Robot tooling	JINGGONG ROBOTICS+OTHER	SET	1
		Safety fence	LOCAL	SET	1
7	Side panel, front door and back door panel welding unit	Welding robot KR120 R2700 extra HA	KUKA	SET	2
		Welding robot base	JINGGONG ROBOTICS	SET	2
		Welding robot sliding rail 10m	JINGGONG ROBOTICS	SET	2
		2-position turntable AT1000	FIBRO	SET	4
		2-position turntable servo drive	SEW	SET	4
		2-position turntable base	FIBRO	SET	4
		H type slewing frame	JINGGONG ROBOTICS	SET	4
		Flexible tooling bottom plate (including quick-fix parts)	DING SHENG TIAN/OTHER	SET	8
		Zero point positioning tooling	AMF/OTHER	SET	16
		Single axis positioner (including reducer)	JINGGONG ROBOTICS +SUMITOMO	SET	8
		Single axis positioner servo motor	JINGGONG ROBOTICS +OTHER	SET	8
		Welding fixture	JINGGONG ROBOTICS	SET	8
		Welding robot KR60 HA	KUKA	SET	1
		2-axis positioner DKP400	KUKA	SET	1
		Welding robot base	JINGGONG ROBOTICS	SET	1
		2-axis positioner welding octagonal pore welding platform	LOCAL	SET	1
		平面焊接孔隙平台2.4X1.2m	LOCAL	SET	2
		Plane pore welding platform quick-set-up fixture	LOCAL	SET	1
		Laser welding supporting system	TRUMPF	SET	1
		Gun cleaner	TBI/OTHER	SET	1
8	Welding room unit	Bit welding room	JINGGONG ROBOTICS	SET	1
		Double layer welding room	JINGGONG ROBOTICS	SET	1
		Safety fence	JINGGONG ROBOTICS	SET	1
		AC	LOCAL	SET	1
		Shutter door W=3m	LOCAL	SET	2
9	Dust removal system	Big welding room DFO 3-18	Donaldson/OTHER	SET	1
9	Dust removal system	Small welding room DFO 2-2	Donaldson/OTHER	SET	1
10	Laser welding system	激光器：TruDisk 6001+1个振镜PFO33+1个PFO3D	TRUMPF	SET	1
		Voltage regulator	TENGEN	SET	1
		Chiller MCWL-250	TONGFEI	SET	1
11	Camera, screen & camera platform		JINGGONG ROBOTICS+LOCAL	SET	1
12	Electric control system		SIEMENS/OTHER	SET	1
13	Relative mechanical annex		JINGGONG ROBOTICS+LOCAL	SET	1
14	Relative mechanical annex		LOCAL	SET	1

Automatic cabinet panel welding line main equipment technical parameter

automatic loading 4-axis SCARA robot ：EPSON G6 653SR
laser process testing station welding robot: KUKA robot KR60 HA R2033
laser welding system :TRUMPF laser TruDisk6001+1 galvanometer + 1 galvanometer PFO3D.	The welding vibration lens can perfectly solve the problem of rapid laser welding in the working area, and the switching time between point and point, track and track can be less than 30 ms, which can greatly improve the welding cycle time. Through the corresponding professional software TRUMPF can set and optimize a lot of laser welding process parameters, and edit the required welding trajectory (welding points), when the need for flight welding can also match the robot action fitting programming to achieve flight welding.
vibrating disc
automatic stud welding system	screw automatic feeding system fixed type stud welder
Electric control system	The control system uses SIEMENS PLC to collect signals such as sensors into the CPU through the network, and deliver the processed signals to the execution components through the network. Configuring electrical control cabinets and operating boxes Pneumatic components uses FESTO or SMC. System configured with mechanical button switch start. Operation has manual / automatic mode. Relative parameters can be set from HMI. Safety fence in place to ensure personnel safety. Floor: Cement floor, conventional workshop type. After the whole work station is leveled, it can be fixed to the ground by chemical bolts or expansion bolts; the bearing capacity of the ground is required to be <25KN/ m2 Temperature: 5~45℃ Humidity: 2075%RH Vibration: less than 0.5G Power: 380V±10%; 3 phase 5 wire, 50HZ±2%