• Advancements


• Specialized Applications


• Integration of Equipment
  
• Costs Coming Down, Ease of Operation Open Market

The robotics world over the last ten years is definitely a better place, thanks to advancements in technology that have left an indelible mark on the industry. The good news for users is that costs are coming down and equipment is easier to use, boding well for manufacturers, as markets for new business open.

A decade ago, motors were DC; now they are AC, generating heat on the outside as opposed to the inside of the motor. The change has a strong effect on kinematic performance. Armatures are smaller for improved speed. Encoders are now absolute as opposed to incremental, which means that as soon as the robot is turned on, it knows where it is instead of having to find its place, increasing speed of operation.

Together with the change in motors, improvement in the electronics arena in terms of chips, drivers, and CPU power also has had tremendous impact, allowing for the development of software to improve robotic "thinking" and upgrading response, speed, and performance.

This overhead view is of the robot located within a Panasonic PerformArc 100 work cell, installed by Praxair at CPR Welding, Slinger, WI. Praxair has also installed similar cells at both Pressed Metal and Pingel Enterprises. Visible in this view is a distributor-friendly pre-engineered cell, which is supplied with all necessary safety fencing (shown) and components enabling the cell to be up and running within only a few hours of delivery.

Highly specialized software enables industrial customers to document actual arc welding operations in real time and to retrieve data verifying that welding specs are within planned parameters. It provides data records to show that processes are maintained within upper and lower control limits (if desired), offers communication up and downstream, and the ability to get information via e-mail or pager to management for analysis and/or timely maintenance. Utilizing information in this way ultimately harnesses the power of the robot and dramatically upgrades robotic welding productivity and quality.

Robots used to be general-purpose motion devices. Now they are more specialized to meet customer needs. In the robotic arc welding arena, application software fills a highly defined niche, allowing for total integration and interface of equipment, fine tuning of arc transfer characteristics response from weld to weld and even within one weld, and faster communications among the controller, robot, and power supply. Shown here is a pre-engineered robotic arc welding work cell, under evaluation at Richmond, KY-based Progressive Systems, a Panasonic Factory Automation systems integrator.

Another significant then-versus-now difference is that in the past, systems integrators filled simple requirements. Today pre-engineered work cells, which are highly successful in arc welding areas and the ideal entry robot for the smaller job shop, for example, are available within a week to do the job through integrators and welding supply distributors, at a reasonable price. One solution can handle a variety of applications.

Robots now also appear to be friendlier. When people see the operation, the fear factor disappears. They see results. The first-time purchaser is able to buy with more confidence, less risk and expense.

Perhaps the most significant trend in the robotic arc welding arena is that the cost:value relationship of equipment is coming down, which by increasing a fabricator's capabilities has opened doors for new customers and additional models are readily available for varied applications. The current concept of robotization and pre-engineered work cells has made a world of difference.

Indeed robots and the companies that supply them are more specialized. At the same time, robots are suited for more people and are easier to operate. Common sense still rules, but today lesser-skilled people can operate a robot effectively. Software does it all.