ESAB expands automation portfolio with cobot welding cell

These solutions boost arc-on time, and a cobot can easily increase output per operator by 150 to 250% compared to manual welding.

"The ROBBI 360 cobot and Tracfinder mechanised tractors overcome traditional barriers to welding automation, especially among small- to medium-sized enterprises," says Tom van Dooren, Global Product Manager, Integrated Robotic Systems and Mechanised Solutions, ESAB.

"They deploy quickly and easily, feature operator-friendly controls, do not require robotic programming knowledge and are suitable for high-mix/low-volume and medium- to high-volume production runs. ESAB automation solutions enable fabricators and manufacturers to leverage the talents of existing staff to increase output per employee while also improving the operator's working environment."

ROBBI 360 Cobot

ROBBI 360 is delivered as a complete "plug and play" cobot package that has been weld-tested before shipping. Connect power, shop air, filler metal and shielding gas, and it is ready to weld. 360 includes a Universal Robots' UR10e cobot, a 3469 x 2228 x 2628mm cell enclosure for protection, turntable with a 1200 x 800mm work envelope, an ESAB Aristo 500ix or Aristo Edge 500R power source and matching feeder, an integrated fume extraction hood and all electrical and gas connections.

The entire assembly is mounted on a skid with fork truck pockets for easy positioning and redeployment. The fully-enclosed workstation has rigid aluminium cell walls and a rugged steel base that ensures no vibration and a stable TCP (tool centre point) that prevents having to make adjustments after moving.

ROBBI comes with two welding options. The Aristo Edge 500R power source and RoboFeed Edge robotic wire feeder ensure precise arc starts and enhanced stability across four advanced WeldModes - THIN, ROOT, ROOT Pipe and SPEED - as well as an Advanced Pulse WeldMode. All WeldModes enhance arc stability, offer more control at faster travel speeds and reduce spatter for less post-weld clean-up. The Aristo Edge platform also empowers independent development of synergic lines and process updates. The Aristo 500ix, paired with the RobustFeed wire feeder, delivers proven reliability in the toughest industrial conditions and features pre-programmed synergic lines for MIG and pulsed MIG applications using most welding alloys.

Mechanised tractors

Tracfinder Rail is designed for welding in all positions using high stability rails and a rack and pinion transmission to prevent slippage at speeds up to 180 cm/min. The teaching software empowers users to easily program precise weld paths with up to 50 points, ensuring accuracy along the weld seam.

The Tracfinder Wheel autonomous welding tractor features a magnetic base with 28 kg of magnetic force that enables it to operate in all welding positions at speeds up to 200 cm/min, including vertical up and down, overhead and on the inside and outside diameters. The new innovative tracking software adjusts the Tracfinder Wheel's trajectory based on torch position settings, eliminating the need for rails and minimising setup time.

Dual motorisation with independent left/right control and 4-wheel drive deliver superior traction and stability in any welding position. The Advanced remote control lets users adjust direction while the tractor is moving, much like a remote controlled car.

Designed for maximum flexibility, Tracfinder tractors feature a common operator interface that is available with Standard, Advanced and Advanced+ control packages. The two Advanced packages feature a remote control interface for operation up to 20 m away, as well as advanced software. The Advanced+ package includes a communication box enabling seamless two-way communication with the Aristo Edge 500R power source and RobustFeed Edge wire feeder; otherwise, Tracfinder works with any brand of welding power source.

The Tracfinder advanced controllers enable users to save up to 30 jobs, storing programs for tractor parameters that include weld speed and length, delays, repetitions, stitch welding, back-step welding, three standard weaving patterns, the ability to customise the weave dwell time, width and speed, and a special multi-axis weaving function that combines horizontal and vertical weaving. Because all systems feature a common central control base and components, users can start out with the Standard control and upgrade to an Advanced or Advanced+ control.

"By making continuous welds, tractors reduce rework associated with start/stop defects," notes van Dooren. "In applications where customers expect uniform weld bead profile and penetration, mechanised tractors deliver consistency without the cost or complexity of automation. They also reduce operator stress by reducing fume and UV radiation exposure, as well as reduce welding in uncomfortable positions."