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Within the scope of their technology partnership the companies KALTENBACH, CLOOS, AUTOCAM, and bocad present a new, highly automated robot welding installation. The innovative KWR 1001 system was developed especially for the steel construction industry and contributes significantly to the automation of fabrication processes.
The highlight of this installation is the automatic program generation of 3D CAD data via DSTV interface with XML amplification. The result for steel construction companies: reduced welding times and personnel costs, as well as minimised material processing times.
Unlike single part fabrication – which is mainly carried out by means of ultra-modern CNC machines – stapling and welding is still carried out the conventional way in steel construction companies. Based on this fact, the newly developed welding robot KWR 1001 provides enormous potential of rationalisation. The total welding time is reduced to a quotient between a third and a fifth of the time needed by the conventional technique – with constant high quality of the welding seams.
The efficient integration of the welding process into the internal material flow will additionally minimise the processing times of material. Subsequently, personnel costs of steel construction companies are reduced significantly. The robot welding installation KWR 1001 can handle parts which weigh up to 600 kg, are 2,000 to max.12,000 mm long, are 50 to max.450 mm broad and which are 100 to max.1,000 mm high.
After the manual stapling of parts and the subsequent mounting on the robot welding installation the robot programs will automatically be generated on the basis of 3D CAD data. The data transfer is done on the basis of NC-DSTV and the by bocad’s newly developed XML amplification. As well as the geometry of all parts of a welding group the part type, welding preparations, the orientation of the parts to one another, the welding seam geometry, welding seam size and weld type also belong to the transferred information.
Generally accepted protocols are set up within the AUTOCAM software MOSES for the automatic generation of the welding sequence. These general rules can be adapted to any customer requirements. Subsequently the welding installation KWR 1001 provides an optimal dimensioning and welding of the parts.
The technological cooperation of these four companies is based on decades of experience of KALTENBACH in concern of the conception of machines and installations for steel construction and the capacious know how of company CLOOS in the range of special installations especially welding robots. AUTOCAM is an expert in the range of offline programming of cutting and welding processes. bocad developed the XML amplification of the DSTV interface. This makes the software specialist to the one CAD developer worldwide who provides an interface for the steering of a welding robot for steel constructions.
Technical features include:
- Power source (optional): 250/500/600 A
- Wire gauge: 1,0/1,271,6 mm
- Number of robot axes: 6 + 3 linear
- Number of stations: two
- Number of rotating devices: 2×2
- Sensors: tactile sensor, arc sensor
ABOUT HANS KALTENBACH MASCHINENFABRIK
KALTENBACH was founded in 1887 and has remained a family-run company. KALTENBACH is one of the world leading manufacturers of machines for processing of steel, aluminium and other non-ferrous metals. Their products include circular band-saws as well as installations for profile processing, sheet metal forming, and punching and cutting installations.
KALTENBACH’s service does not only provide product development, but also production, installation and after-sales support. KALTENBACH is headquatered in Lorrach, Germany.
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