Case Study: Utility Trailer
Panasonic Factory Solutions CompanyPosted 05/15/2008
Case Study: Utility Trailer
Application: Welding 48-foot aluminum trailers
Industry: Welding
Situation:
(Enterprise, AL) Utility Trailer's original robotic MIG welding system to fabricate 48-foot aluminum trailers was operational but not efficient. The goal was to make the system more efficient, provide adequate training for operators, improve cycle times and eliminate distortion.
Solution:
Panasonic Factory Solutions Company of America (Buffalo Grove, IL) and systems integrator, Progressive Systems, Inc. (Richmond, KY), designed and installed a six-robot line (AW-005AL and VR-006AL) in which the six robots operated simultaneously.
Results:
- Overall, the robotic cell increased productivity significantly. Utility Trailer previously was able to produce 11 sets of 48-foot rails on the robot in a two-shift workday. Now they produce 16 rails on one shift each day.
- The strength of the welded rails increased 23%, resulting in measured strength of 39 to 40,000 pounds in comparison to 32,000 pounds of force previously.
- Improved aesthetic welds were achieved, and are important because they are visible to customers.
- The RA-350 welding power source designed specifically for aluminum MIG welding, provided consistent, stable, and instant arc starts.
- The wire feeder was documented to achieve up to a 50% reduction in the force required to feed either soft or hard .045-in. dia. 4043 aluminum welding wire, when compared to head-to-head conventional feeders.
- A touch sensing system used on each of the six robots, ensured the arc started in the weld joint every time, regardless of the thermal distortion.
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