In the field of automation technology, many users are far less interested in precision single automation parts than those that meet their requirements. ASB Automation Technologies provides this “turnkey†automation project. In the implementation of an automation project, the automation technology they use can do the same.
In the past year, ASB Automation Technologies of Nufringen has completed many different industrial automation projects: from factory automation to logistics automation. Because their automation technology is an automation solution based on a modular structure, their automation solutions are innovative and versatile, enabling automation in different areas. These include: intelligent inspection systems, automated welding systems and automated weld quality inspections, as well as flexible and convenient automated workshops.
In a wind power project, the steel ring of the tower needs to be welded, and the welding quality inspection uses the AWI automated welding quality inspection system. A tower of up to 100 tons of wind turbines is to be installed on the tower, and the tower must be able to operate normally under various environmental conditions, when the tower itself vibrates and withstands wind. Therefore, high reliability is required in the manufacture of wind power generation equipment for welding reliability and welding quality. This is also the ideal application environment for AWI's automated welding quality inspection system. In this automated environmental quality inspection system, it is necessary to develop an automated inspection method suitable for a variety of weld structure and geometry.
Automated system to meet various needs
In this automation project, a six-coordinate robot is used. Both the welding tongs and the testing instruments can be installed on the robot arm (see Figure 1). Communication between the robot, the welding control system and the detection device is done by the SPS programmable controller. When working, it first detects the optimal position of the weld bead, and starts welding after the robot's working position is automatically compensated. At the same time, the welding quality inspection device checks the quality of the weld. When the quality of a certain weld is found to be unqualified during the inspection, it will be reworked and re-welded immediately. At the same time, the image of the weld seam with different quality is saved in the database. This allows for the analysis of recurring weld defects and optimizes the welding process if necessary.
With this automated welding quality inspection system, weld quality can be verified for butt welds, V-welds, lap welds and fillet welds. This device, which combines welding, inspection and rework, has so far been unique.
And most importantly, the reliability of its inspection results. In the system design, it puts a lot of effort into the correct lighting scheme and the welding quality evaluation algorithm language. At the same time, the use of such a system should be very flexible; it can be integrated into the assembly line as needed or used as a stand-alone solution. Through different configurations of the software system, it can adapt to different application needs
The software can be configured to apply the automation system to different environments.
“Initially, this solution was developed for tower welding of wind power equipment, but it can be used in many other projects.†Mr. Jürgen Decker, senior project manager at ASB Automation Technologies, said: “For example, we can be simple, It is convenient to transplant the AWI welding quality inspection system into the weld inspection of PVC material welding in the automotive industry, or in the welding quality inspection of automobile bumpers. Because of the high precision in the welding of these components, it is very important. In general, the ASB system will automatically complete the setup when the device is first commissioned. Therefore, extensive technical training for the operator ensures that the user can configure the AWI system to suit the new application.
In addition to the automotive industry, typical applications for such automation systems include all where welding is required and the quality of the weld is to be inspected. For example, this automated welding quality inspection system can help the manufacturer in the welding of pipe fittings or in the production of steel furniture. It can shorten the production time, reduce waste and reduce user returns. The time of production and processing cycle, while improving the quality of welding and user satisfaction.
Another automation solution with a wide range of applications is the Mobile Automation Workshop ASBFlex. Today, it is impossible to avoid (semi) automation technology issues when there are high demands on product quality in many industrial applications or when working within a cost-saving framework. The complete transformation of the entire production process does not make much sense in many cases, and sometimes it is not feasible.
Mobile technology for mobile
Mobile automation workshops are a very suitable solution when it comes to different time periods, different locations and different automation requirements. Mr. Decker said: “An injection molding plant has five injection molding machines that produce different products at the same time, some of which are pelletized raw materials for injection molding, and others are plastic products. They are packaged after the injection molding is completed.â€
The mobile robot workshop ASBFlex can be easily moved from one device to another using a forklift. The structure of the work room can be designed according to the user's requirements.
In order to avoid an injection system with an automated system to reduce investment costs, they chose a mobile robotic workstation, a robotic workstation that can be transported between injection molding machines using a forklift (see Figure 4). Using a bar code reader or RFID radio frequency scanner, it is possible to determine the correlation between the mobile robotic workstation and the injection molding machine to accurately determine the relative position between the workstation and the machine. After entering the part barcode, the robot knows what should be done for this injection molding machine. By connecting the power supply and compressed air, the robot can work normally. The time to move, connect and commission the mobile robotic workstation between machine tools depends on the task to be completed and the structure of the work space, which can be completed in a matter of minutes, up to 1 h.
The flexible mobile automation workshop has been successfully used in different automation projects such as pipe production, grinding wheel sintering and final assembly.
Mr. Decker said: “Because all of the mobile automation workshops use flexible automation components, this solution can be used in many different applications. We use this in different automation projects. The mobile automation workshop completes the automation of some pipe fittings, grinding wheel sintering, and final assembly to meet the needs of users. If this automation solution is also suitable for use in other projects, then It will be the most ideal."
AWI's automated welding quality inspection system can also be built into mobile automation workstations for flexible use in different production locations. In principle, ASB's focus is on providing automation technology that meets user requirements (see Figure 6).
Mr. Decker said: "If this automation solution is also suitable for use in other projects, it would be ideal."
ASB Automation Technologies is a wholly-owned subsidiary of OMRON, which has all the skills and expertise required in the automation field, from planning and design to installation and commissioning. It is mainly engaged in research and development and providing solutions for production automation processes. The automation system is optimized for improvement.
The company has three main components: OMS automation solutions in Lisbon, Portugal, responsible for design, cost accounting, procurement and production processing; P3S automation Projects in Barcelona, ​​Spain, for sales, procurement and project packages; and ASB automation technologie in Nurringen, Germany. Responsible for sales, procurement, technical services and project support. In 2001, the company consolidated its experience in automation, logistics and LCIA low-cost intelligent automation to achieve a complete solution for complete robotics, quality inspection and electronic projects up to SPS and HMI programming. .
In addition to these technical services, they can also undertake research and development tasks such as AWI automated welding quality inspection system and mobile automation workshop ASBFlex.
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