PowerOn was contracted to provide a full turn-key system for a robotic welding cell. PowerOn was also responsible for the design concept of the cell, the design and manufacture of the robots 3 EOAT, as well as the welding fixtures.
This weld cell consists of 4 Fanuc robots, 1 of which is a 6-axis robot mounted upside down on a 10ft high, 55ft long overhead gantry. This robot is a 350kg payload material handling robot. On the floor there are an additional 3 welding robots.
The overhead robot loads different structural metal pieces into a welding fixture, where they are welded together by a robot. Once welded, the part is picked up and placed on 1 of 2 other fixtures, where a metal skin is also welded by another robot. The final structure is then palletized by the overhead handling robot.
The control system consisted of an Omron PLC and HMI, with DeviceNet communication to the robots.
The client originally had 4 staff members assembling and welding the entire structure by hand. The new fully automated weld cell only requires a single operator.