WELDING
Integrated welding cell helps to cut production times by two-thirds
A
n ABB robotic welding cell is enabling
agricultural machinery manufacturer
Shelbourne Reynolds to dramatically reduce production times for its range of articulated hedge cutting tractor attachments. Handling the several hundred welds entailed in the production of the attachments, the cell has so far cut welding process times by 66 percent compared to the company’s previous manufacturing process. The installation features a specially adapted version of ABB’s FlexArc cell, which brings together a robot, positioner and the welding equipment needed for the process into one integrated package. The cell is used to handle the company’s more difficult and time-
consuming welding tasks. As well as the hedge cutting attachment, the cell is also used to produce other equipment, including a grain stripper and subassemblies for combine harvester headers, both of which involve complex welds. “The decision on which tasks to automate with the robot was based on the amount of time they took compared to our existing process and the potential savings that could be achieved,” explains Michael Scarfe, Manufacturing Manager, Shelbourne Reynolds. “For this reason, we introduced a cut-off point whereby anything that previously took an hour or more to weld was allocated to the robot cell.” The result has been a significant reduction in welding times, with products now being
welded in one-third of the time previously required. Not only that, but complex welds, such as those involving welding around pipes and tubes, are now performed to a much higher aesthetic standard than previously. “Circular interpolation processes involving welding around tubular objects can be a challenge for even the most skilled manual welders, particularly when time is of the essence,” says Mr Scarfe.
Compared to the previous team of six needed to handle the welding process, the robotic cell now only needs one team member to supervise one of two production shifts. “It would be true to say that some of the team were understandably apprehensive when we first introduced the idea
of a robotic welding cell,” admits Scarfe. “However, the idea was always to use it to complement, not replace, our manual operations.” Proof of this is demonstrated by the fact that no-one has been made redundant since the cell was introduced. Comments Scarfe: “Finding skilled staff is very hard, particularly when it comes to processes such as welding and plating. We are therefore very keen to hang onto the people we’ve got and to find ways to utilise their expertise in the manufacture of other products.” One example is the manufacture of the Stripper Header used on larger combine harvester vehicles, which, at 42ft in length, can be produced more economically by manual welders than a robotic cell. “As a small
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IMT April/May 2014 29
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