Technical task
Development of a robotic fixture for welding metal fences, railings, and structures
Client: LLC "Door Systems VERON"
Production: Murovane village, Budivelna St., 30, Lviv region.
1. Project goal
To develop a universal rotating fixture table for robotic welding of metal structures, which will ensure:
- simultaneous operation of two welding robots;
- high precision of positioning parts;
- quick reconfiguration for different products;
- minimization of loading and unloading time;
- scalability for new types of products.
- Equipment selection
2. Main products
The fixture must ensure the assembly and welding of:
- railings;
- balcony fences;
- terrace fences;
- protective fences;
- sectional metal structures;
- frames made of profile pipes.
3. Materials of products
Main material:
- black steel;
- galvanized steel.
Profiles:
- 20×20 mm;
- 30×30 mm;
- 40×20 mm;
- 40×40 mm;
- 60×30 mm;
- 60×40 mm;
- other profile pipes as needed.
Metal thickness:
4. Requirements for the fixture
Design
To provide for:
- a rigid spatial frame;
- a modular adjustment system;
- interchangeable stops;
- interchangeable templates;
- the ability for quick size changes of the product.
The fixture must ensure:
- positioning accuracy ±0.5 mm;
- repeatability of products;
- exclusion of deformations during welding.
5. Rotating table
To provide for a rotating mechanism:
- manual or automatic;
- rotation 180°;
- preferably 360° rotation with position locking.
Requirements:
- load capacity of at least 500 kg;
- fixation in working positions;
- absence of play.
6. Operation of two robots
To provide for the possibility of simultaneous operation of two robotic welding stations.
It is necessary to:
- exclude conflict zones of the robots;
- provide for working zones;
- ensure accessibility of all seams;
- consider future expansion.
The engineer needs to develop a layout scheme for the robots around the fixture.
7. Pneumatic clamps
The fixture must be equipped with:
- fast-acting pneumatic clamps;
- adjustable clamping force;
- quick replacement of clamps.
Requirements:
- reliable fixation of thin-walled profiles;
- absence of deformation of the workpiece;
- possibility of group control.
8. Welding
To provide for the possibility of performing:
Laser welding
- continuous seam;
- hidden seam;
- decorative seam.
MIG/MAG
- tack welds;
- short seams;
- continuous seams.
9. Equipment
To provide for:
- a base system;
- measurement points;
- interchangeable cassettes;
- interchangeable templates.
It is necessary to ensure the possibility of reconfiguration:
- up to 15 minutes for a new type of product.
10. Safety
To provide for:
- protective barriers;
- light barriers;
- emergency stop;
- protection against robot collisions.
11. Documentation
The design engineer must provide:
3D model
- SolidWorks / Inventor / Creo.
Set of drawings
- general view;
- assembly drawings;
- detailing;
- specifications.
Calculations
- rigidity of the structure;
- load;
- center of gravity;
- calculation of the rotating node.
Production documentation
- material list;
- cutting maps;
- list of purchased components;
- list of pneumatics;
- list of sensors and automation.
12. Expected result
To obtain a universal robotic rotating fixture for the serial production of metal fences and railings with the possibility of simultaneous operation of two robots, quick reconfiguration, and high repeatability of products.
