Intelligent Robot Solutions: Fanuc Robot Faces Challenges Head-on with Their Extensive Line of Robots.

APPLICATION: ARC WELDING
A wheelchair manufacturer stumbled across a problem while in the midst of introducing his new line of lightweight steel and aluminum wheelchairs. There were eight workers assigned to the job of brazing all of the frame components for these products. In the first year, production rates reached 2,500 wheelchairs, leading plant management to the conclusion that the current project team was unable to keep up without hiring additional workers.

The company had a large goal in mind, and it didn't take long for them to realize that they needed to find a better method to meet these production goals. With this dilemma looming large, the wheelchair manufacturer enlisted the help of Fanuc Robotics, in particular, their robotic arc welding.

The company needed a robot to weld small diameter tubing with wall thickness of 0.049 in. to 0.065 in. Additionally, the robot welders would also be required to turn tight corners when welding chair joints.

Fanuc Robotics worked together with Lincoln Electric developing a robotic arc welding system to weld mild-steel wheelchair side frames and foot rests. The integrated companies' solution included robots, tooling, welding equipment, software and system integration.

THREE ROBOTS DO THE JOB OF 45 WORKERS
Fanuc and Lincoln Electric's teamwork allowed the wheelchair manufacturer to be the first to robotically weld all frame components. Growing on that success, they currently have three robotic arc welding cells and plan to install a fourth.

In order to meet the production goal of 45,000 wheelchairs, the company would need to have 45 brazers working two shifts. With that amount of labor content, they would have had a difficult time sustaining profit.

SYSTEM DESCRIPTION
The solution to the wheelchair challenge came in the form of three robotic welding cells using: a FANUC Robotics ARC Mate 100 robot; Lincoln NA-5R control and wire drive; a Lincoln Idealarc CV-400 power supply; part-specific tooling and FANUC ArcTool application software. Two cells produce side frames of six components and subassemblies, and foot rests. The third weld cell welds two side frames and foot rest assemblies, completing the wheelchair structure.

WORKERS RETRAINED TO OPERATE ROBOTS
The employees who started this project by manually brazing the wheelchair frames finished this project after training, during system operation. The manual brazers were trained to operate and maintain the robotic system. Following tooling setup, an operator is responsible for loading a fixture onto a 180° turntable positioner. The two-station positioner allows the operator to load parts and to remove welded assemblies while the robot begins work on a second assembly.

Once welding is complete, the operator inspects each weld for cosmetic quality. As a final measure for ensuring structural quality, the company performs destructive tests three times per day.

SYSTEM BENEFITS
Since the installation of these robotic welding cells, weld reject is less than 1%, and require only manual touch-up at a manual brazing station. Cosmetic quality has also been significantly increased.

Production rates have taken a turn for the better, seeing much improvement. Manual brazing of wheelchair frames took as long as 45 minutes. Robotic welding has reduced frame production time to a mere 3 minutes.

APPLICATION: MATERIAL REMOVAL
The challenge of improving the finishing process of femoral orthopedic implants was brought in front of an orthopedic implant manufacturer. The company's current manual finishing process raised concerns with production time, material waste and rework costs.

M-16iB robotic femoral implant polishing system.

ACME Manufacturing Company, Auburn Hills, MI, stepped up to the plate with what they believed was just the solution the manufacturer was looking for. ACME's plan was to implement a robotic finishing system that utilized a FANUC Robotics' M-16i R-J3 robot to emulate the movement of manual polishing orthopedic implant devices.

The M-16i RJ-3 robot provides the necessary movement, strength and reliability that they need. ACME and FANUC Robotics did a great job of integrating a robotic system that has led to a predictable manufacturing process for their company.

SYSTEM DESCRIPTION
The problem solver, FANUC's 35-pound, 6-axis robot, works with four ACME-designed and built finishing heads to metal finish an orthopedic implant in one continuous step. Specialized tooling orients, fixtures and polishes a single component to within a ± 0.005-in. tolerance. ACME is the proud developer of these tools. A touch screen operator interface panel enables the machine operator to create, retrieve and change part programs.

ACME's application software uses human- like brainpower to store and manage all part files. On top of that, a set of user- friendly manuals and engineering documents are stored on the personal computer for easy operator access. ACME has designed off-line troubleshooting capabilities by using a modem connection. ACME's modem connection allows the company to upgrade application software or modify the system operations from a remote connection.

ROBOTS INSTALLED
Following the design, build and integration of the ACME robotic cell, the unit is shipped to the customer as a single module. The majority of these cells are installed at a user's facility and are up and ready to get to work within two business days.

SYSTEM BENEFITS
ACME's robotic cell offers its users a number of cost-saving benefits. The polishing time of an orthopedic implant device can be significantly reduced from 30 minutes to 12 minutes. These robotic systems nearly eliminate scrap and rework, and perishable costs are substantially reduced. Compared to manual finishing operations, robotic cells use fewer belts, buffs, compounds and contact wheels. Parts can be run in small batches and programs, while process data can be stored and retrieved via an Ethernet link.