Triada Ltd Co (Triada-Welding) presents another interesting Robotics Project, completed in late 2019 for the Zaporozhye metallurgical enterprise LLC "ZLMZ". The project was carried out on a turnkey basis and, starting with concrete works, included design works, fabrication, installation and integration of RTC into the already existing production cycle.
Zaporizhzhya Foundry and Mechanical Plant is part of the METINVEST group, is engaged in the production of cast iron, steel and ferroalloys, production of hollow pipes and steel fittings; production of building metal structures and parts of structures, finished metal products; machining of hardware; repair and maintenance of machinery and equipment for industrial use.
Triada-Welding was founded in 1992 - a modern engineering company, system integrator of industrial welding robots, has its own R&D center, focused on the industrial sector, develops additive technologies. Triada Co., Ltd. is the official integrator of YASKAWA industrial robots (Japan) in Ukraine. Specializes in the design and development of technologies using industrial robots to automate welding processes, including contact welding, surfacing, moving products. The company's specialists have undergone special training at leading European companies, which is confirmed by certificates, they are constantly improving their level of knowledge, exchanging experience with specialists from world developers. The company has extensive experience in the field of welding technology.
This robotic welding complex was created for the production of serial products, namely: welding of metal sleepers for mining and processing plants and expansion joints, it was designed and implemented in existing production.
The complete set of RTC included:
- welding robot Yaskawa MA 2010 with DX 200 controller included;
- positioner RM-2 750S3D, has three axes, multifunctional, equipped with 3 servomotors with a load on the station of 750 kg and a distance between the faceplates of 3000 mm, included;
- contact tracking system Seam Finding with the system of online tracking of the welding joint for multi-pass welding ComArc;
- TPS 500i welding equipment included;
- robot periphery, burner cleaning system, shielding gas saving system;
- assembly and welding equipment;
- welding protection systems, light gates and other equipment.
Industrial robot Yaskawa MA 2010 (Japan) was designed specifically to solve high-tech welding problems with work at high speeds. This significantly reduces the processing time of products. MA 2010 robot can be placed on the floor, ceiling or wall, it has a significant range (over 2 m) and increased load capacity (up to 10 kg), which allows you to weld bulky products using powerful and heavy welding torches. It should be noted that the robot MA 2010 has the highest speeds of movement along the axes in its class of robots.
The DX 200 controller - energy saving - was offered for this Project. In the future, it will be possible to connect several more robots to the robotic complex and strengthen the production cycle. Using patented co-operation technology, the DX 200 controller is free to perform multi-purpose tasks, including co-operation of 8 robots and peripherals (up to 72 axes in total). It has advanced control systems: built-in collision detector, faster input-output response, increased processor speed, etc. The operator exercises all control over the processes from the programming console, so the controller itself can be located remotely. The use of the industrial positioner RM-2 750S3D as a part of the robotic complex allowed to create the most compact and highly productive space for mass welding of products which need to be rotated during welding. The large distance between the faceplates allows in the future to complete this cell with one or more jobs, thereby increasing the productivity of RTC in 2 and 3 times, respectively. The positioner is equipped with a Yaskawa servomotor, which means that the robot and the positioner are fully synchronized with each other and have an accuracy of simultaneous movement of 0.08 mm.
The TPS 500i welding machine (Austria, Fronius) interacts with the user on an intellectual level, all welding modes are built in the device. The device also has a large database of synergistic programs for welding. The system has high-speed data processing, the option of accurately determining the state of the welding process (which significantly improves the separation of the drop), the welding process is carried out with reduced heat input. The penetration stabilization function significantly compensates for the effect of changes in the departure of the electrode on the welding result. As a result, welding is carried out at high speed stably and with uniform penetration.
The WF25iR wire feeder (Fronius, Austria) is equipped with 4 carbide rollers, which ensure a stable supply of welding wire.
The Abicor Binzel burner cleaning system (Germany) cleans the nozzle from welding splashes, applies liquid from the sticking of welding splashes on the working parts of the burner, and performs wire cutting after the welding process (removal of the drop after welding).
The Seam Finding system starts the function of checking the start and end point of the seam, the robot checks the contact method of the point and, if there is a shift, corrects, after which the welding process takes place. Comarc's online butt welding tracking system adjusts the torch position during welding. Adjustments are made during welding and do not affect the operating time.
Device for saving shielding gas EWR (Abicor Binzel) prevents the formation of peaks during the welding process, synchronizes the gas supply with the welding current. This system saves from 40% to 60% of shielding gas.
The Project complies with the latest security options, tracks the condition of equipment and the location of operators in work areas.
All works on installation and start of RTC were executed in time. The project also includes comprehensive service, both warranty and post-warranty.
Askaynak welding materials (Turkey) were also selected for the operation of the technological complex, and protective welding systems were designed and manufactured. All welding technologies have been tested in Triada-Welding own technical center.
Special trainings on programming and control of RTC were conducted for the specialists of Zaporizhia Foundry and Mechanical Plant.
Triada-Welding is a certified representative in Ukraine of the Austrian company Fronius - a world leader in the development and production of welding equipment and intelligent welding systems, and Triada-Welding is a certified representative in Ukraine of the global company Abicor Binzel (Germany).
It is important to emphasize that Triada-Welding is the first in the world and the only one in Ukraine to have CFD compliance certification, once every three years undergoes full certification of the European standard, many years successfully confirming the professionalism and qualifications of its specialists and compliance with all international standards.
The project allows "ZLMZ" to work continuously and increase the production of parts at the request of the customer. The robot works in 3 shifts around the clock, already achieved a capacity of 200 tons of metal per month. The project showed the latest approaches to the welding process and has already allowed the manufacturer to expand the range of products. Also thanks to the introduction of RTC optimized production process: yes, we managed to avoid unnecessary movement of parts in the shop due to the unique equipment installed on the complex, avoided stripping, now the rolling operation is carried out directly on the conductor, the next stage - welding parts.
Automation, implementation of digital technologies and related business processes have a strong impact on the technological development of the enterprise, economic efficiency of production, environmental standards and safety.
Industry 4.0 is one of the main directions of development of the new technological revolution.
"We make the world а more technological, advanced place by creating smart industries" is the mission of Triada-Welding.