Flexible automation for the production of reinforcement elements

Industrial robots have already been established as a proven solution for the automation of welding processes for several years now. They offer great speed and high precision, resulting in an improved welding quality. Another advantage of industrial robots is the capability of handling heavy and cumbersome parts. However, these robots require high investment costs and comprehensive programming skills. Therefore, they are often too complex for the production of small batch sizes, the use in smaller and medium-sized companies or special applications such as welding of reinforcement.

In comparison, welding cobots are much easier to program. Their lower investment costs allow for quick amortization, thus making them attractive, in particular, for smaller manufacturing companies. Frequently, the limited radius of action and operating area, however, is a disadvantage of standard welding cobots in comparison to industrial robots. This disadvantage, indeed, is a thing of the past with the new mbk welding cobot.

The model of the DSM-L (line) was especially developed for the production of long reinforcement elements and is suitable for a broad target group – from small steel plants up to precast concrete plants. „The DSM-L can process components with a length of up to eight meters, what was only possible with industrial robots so far. Consequently, we offer an exceptional solution in the market,“ states Mario Pfender, the General Manager of mbk. The cobot is traveling on an 8m long linear axis, thus covering the whole working area. Along with the robot, the source of electricity for welding, the wire supply system, the welding fume extraction and the torch cleaning station are moving as well. The integrated 3D welding bench has an impressive dimension of 8,400 x 1,395 mm.

Maximum safety at full capacity

Safety has top priority for mbk. Around the welding cell, welding protection walls safeguard the operator against arc flashes and eye damages. Laser scanners monitor the workspace and ensure that the cobot stops immediately if an operator proceeds too close to the working area. These safety precautions simultaneously allow for achieving the maximum motion speeds of an industrial robot, without compromising safety.

Simple operation and flexible programming

The mbk cobot impresses by its user-friendly operator interface. The software was especially developed and optimized for the cobot and the welding process. The multi-functional handle serves as interface between robot and operator. During the so-called teaching, the welding torch is moved manually to the requested welding spots. Start, end and intermediate spots are stored at the push of a button. No matter whether skilled programmers or beginners – in this way, professional welding programs can be created in a few minutes. Before actually welding, the entire process can be simulated so that the operator can make adjustments, if required.

Efficient working in shuttle operation

Another highlight of the mbk cobot DSM-L is its specific set-up, allowing efficient working in shuttle operation. The workspace can be subdivided into two areas by a partition wall. This arrangement creates room for two work stations, so the operator can prepare or reclamp workpieces on one side, while the cobot is already welding on the other side. This increases the productivity considerably.

Welding is a challenging, physically demanding activity, requiring a high level of concentration. The cobot relieves the staff of exhausting routine jobs and reduces the physical workload simultaneously. An optional single-axis manipulator with counter bearing enables a precise positioning of workpieces up to 2,000 kg in their optimum welding position, eliminating any elaborate reclamping. The axes of manipulator and robot work simultaneously, leading to higher efficiency and speed when welding. The results are exact welding spots in a consistently high quality.

Additional models and versions

Apart from the DSM-L, the models DSM-H and DSM-T are available, which are respectively adapted to smaller component dimensions and their specific requirements and applications.