The experience of cooperation between the companies "Triada-Welding" and
"Grain House" within the framework of the "Industry 4.0" concept
The company "Grain House" is a Ukrainian plant for the production of elevators and elevator equipment, the main partner of which is the American company "Sukup", which occupies a leading position in the international market. The company's activities are aimed at providing a wide range of services for the manufacture and construction of elevator facilities, as well as their comprehensive maintenance. Probably, many of you, when traveling across Ukraine, noticed huge metal cylindrical structures standing along the tracks, in the night moonlight they resemble spaceships. These are bunkers for cooling and storage of grain, flyovers, which are produced by the "Grain House".
"Grain House" is a modern, high-tech plant with flexible mobile production and a clear position of opposing vigorous activity to inert waiting, which is typical for an old-style Ukrainian manufacturer. It is like freedom and doom, where the desire to “be” suggests that the people working in such an enterprise have deliberately made a choice in favor of an active developmental position.
Any process in society should be viewed as a marker of general trends in the country's development, and the essence of any production will tell more than speeches by leaders of various levels about cultural, economic, and political shifts in general. But we will talk about specific implementations: in mid-April 2018, the Zaporozhye company "Triada-Svarka" completed a project on robotizing one of the production units at the Belaya Tserkov plant "Grain House". It is useful for readers to learn about this unique project and the experience of cooperation between two companies looking to the future.
The company "Triada-Welding" is a modern engineering company with a range of activities in the field of robotization of welding processes. Triada-Welding is an official certified representative in Ukraine of one of the world's leading manufacturers of robots Yaskawa (Japan), specializing in the design and development of technologies for robotization of welding processes, including resistance welding, surfacing, and movement of products.
The project on robotization of the welding process for a unique product included the following stages:
♦ study and analysis of the welded product;
♦ study and development of the required welding technology;
♦ design and assembly of a robotic welding complex (RTC), taking into account the available production facilities and the specifics of the production process, integration of the complex into production as a whole;
♦ selection of welding equipment and materials;
♦ design and manufacture of the required conductors, positioners;
♦ design and manufacture of protective welding fences, as well as cleaning systems for welding torch Binzel BRS-CC;
♦ selection and installation of a security system during the operation of the RTC;
♦ training of enterprise specialists in robot management and programming;
♦ assembly and installation of RTC, testing modes, turnkey start-up;
♦ further support and guarantee provision of the RTC operation.
The robotic complex for arc welding was completed and supplied based on the tasks and solutions for this enterprise, taking into account the prospects for the development of the plant in the future. The proposed industrial robot Yaskawa MA 1440 is specially designed to solve high-tech welding tasks with high-speed operation to reduce the cycle time of the product. The ergonomic design allows the robot to be placed in floor, wall and ceiling positions where space is limited. The RTŠ” is equipped with an industrial positioner VMS 500SD, on which a Yaskawa Motoman servomotor is installed, therefore, the welding robot and positioner are fully synchronized and have a positioning accuracy of 0.08 mm. In addition, a high-performance vertical axis positioner is used, which is specially designed for tables with interchangeable positions.
The new generation DX200 energy-saving controller, using patented robot joint control technology, can freely perform multi-purpose tasks, including joint control of 8 robots (up to 72 axes in the future), as well as input-output devices and communication protocols. The robot is equipped with a Fronius TPS 320i welding machine, which interacts with the user intelligently; Fronius WF 25i R wire feeder for stable wire feed burner cleaning system Binzel BRS-CC (this system is a complex solution for automatic maintenance of burner nozzles with the highest level of operational reliability). All robotic peripherals are manufactured by Abicor Binzel.
The Triada-Welding company is the only official representative of the world manufacturers of welding equipment Fronius (Austria), robotic peripherals Abicor Binzel (Germany), certified in Ukraine, and one of the world's best manufacturers of welding materials Askaynak (Turkey).
Triada-Welding has its own technological and service centers, on the basis of which representatives of the "Grain House" were trained to work and control the robot. Director of the company "Grain House" Gabriadze V.Z. highly appreciated this experience of cooperation, which ensures the unity of goals and values, which are of great importance for building the future. The search for new ways of using technologies to change existing production systems is an active position of the "Grain House" company and opens up opportunities for development for the plant as a whole within the framework of the "Industry 4.0" concept in Ukraine.