Compact Remote Welding Head for Robotic Laser Welding

FANUC America Corporation (Rochester Hills, MI) offers robotic laser welding with the FF3000 fiber laser and two robots mounted inside a Class 1 safety enclosure to handle and weld thin steel parts. First, an M-10iA/12S robot picks coupons from servo-driven part stacks and loads a weld fixture mounted to a two-axis servo positioner. Next, an M-20iB/25 robot welds the parts. A new robot-mounted compact remote welding (CRW) head with servo motors manipulates the fine-focused beam into a weave shape pattern tailored to the joint and material. Finally, the M-10iA/12S unloads welded coupons. Then the cycle repeats. The system demonstrates ease-of-use through direct control from the robot teach pendant, allowing the laser and robots to act as one, simplifying the application and maximizing uptime.

FANUC also achieves high-speed cutting and etching to highlight the coordination and synchronization capabilities of a laser system featuring an FF1000iA 1 kW fiber laser. Compact, high-performance, and reliable FF series fiber lasers offer a 500 W to 6 kW range (models FF500iA to FF6000iA) of laser oscillators with direct and high-speed control through the FANUC robot, which is equipped with laser application software that features built-in commands to provide high-speed operation and precise control for a wide range of cutting, welding and additive manufacturing tasks. Additional features and benefits include:

• Synchronized controls, such as laser start and stop sequencing, high-speed pulsing, ramping, gas, and wire feed control that produce high-quality results.
• Supports welding and cutting applications, as well as built-in low power mode for marking applications through simple software settings from the teach pendant.
• High quality and long-life laser diodes offer years of cost-effective, low-maintenance operation.
• New LD power supplies have an improved design, increasing performance through high-speed circuit technology.
• Enhanced back reflection protection and built-in diagnostics improve reliability, and a modular construction makes it easy to service.
• Laser operations user interface allows customers to check system status with a teach pendant or web browser.
• Fast and accurate robot motion optimizes path performance and throughput.
• Rockwell HMI and Safety PLC with indicators to lock doors and switches.

The new CRW head is controlled by a two-axis servo motor that guides a laser beam through a variety of positions and weaved shaped patterns at high speeds along the robot’s path. All shape and path weaving commands are entered through the robot teach pendant, allowing for easy customization and direct control of the laser with the robot and CRW motion. The CRW head is designed for welding applications, but has the ability to mark parts using the laser’s low power function. This head has nine predefined shapes, including circles, zigzags, and spirals. However, custom shapes can be easily developed using the teach pendant. The path weaving functions enable users to bridge gaps for lap or butt welds, join dissimilar materials and provide a bead shape with excellent appearance and strong mechanical properties. The high-speed CRW system provides quick welding times and minimal heat input, making this ideal for many welding applications.

With a 25 kg payload, the M-20iB/25 six-axis material handling robot can handle parts in a variety of applications, such as material removal, machine load/unload, assembly, picking/packaging and part transfer. It offers a rigid, compact, completely enclosed design with a sealed structure (integrated utilities and motors), and a rear or bottom exit for cables. The entire robot is rated IP67 to withstand unique/harsh environments. It has a slim arm to minimize interference with peripheral equipment in tight work spaces, a long reach of 1,853 mm, and a 21% increase in axis speed compared to the previous model. Other benefits include:

• Internally routed utilities offering solenoid valves, camera cables, Ethernet, ASi cable, force and 3DL sensor cable, and EE utility.
• Flexible floor, ceiling and angle mounting options.
• Highly rigid bilateral design and the most advanced servo technology enable smooth motion at high speeds.
• Supports the latest FANUC intelligent features, including iRVision® and force sensing.
• The latest R-30iB Mate Plus controller features an intuitive iPendant with enhanced screen resolution and more processing capability compared to previous versions.

The light-payload M-10iA/12S six-axis robot offers superior axis speeds and acceleration as the fastest handling robot in its class. Ideal for picking, placing and machine tending operations, it provides a 12 kg payload and 1,098 mm reach. Its very rigid arm and advanced servo technology increases acceleration performance to decrease cycle time for higher productivity. Its cable-integrated arm and hollow wrist provide easy operation, even in small spaces. Other features include:

• Highest wrist moments and inertia in its class.
• Hollow wrist and rigid J3 arm for maximum cable protection, easy maintenance and reduced system costs.
• Flexible floor, ceiling and angle mounting options.
• Supports the latest FANUC intelligent features, including iRVision and force sensing.
• The latest R-30iB Mate controller features an intuitive iPendant with enhanced screen resolution and more processing capability compared to previous versions.

FANUC America Corp., 3900 West Hamlin Road, Rochester Hills, MI 48309, 248-377-7000, www.fanucamerica.com.