Bringing a robot into your factory is a complex and often underestimated undertaking. The operation the robot will be performing is often well understood. On the other hand, the procurement, design and integration of the robot (including the fixtures, guarding, and tooling that surround it) cannot be overlooked. The process of selecting and setting up a robot can add weeks or months to the project timeline.
Of course, one good option is to hire a robotic system integrator, a contractor who will set up the cell for you, using their experience and expertise. However, these services can be costly.
Several industrial robot suppliers, including KUKA, offer a third option, known as pre-engineered cells. This approach is to create completely turn-key systems for common industrial stations, such as a welding task, an assembly task, deburring, or even material handling tasks such as palletizing. Since many factories have much the same setup for these types of manufacturing stations, it’s possible to design a cell, complete with robot, tooling, fixturing, and guarding that can simply be delivered, assembled, and plugged in.
In the above video, Mitch Dupon, Sales Manager for Arc Welding at KUKA, shows us a pre-engineered system designed for arc welding medium-sized parts which can fit on a table. The cell features a light curtain controlling access to a rotating table. The table divides an enclosed space in which the robot performs a welding task, from the open space where the operator can load/unload parts. The cell can be properly shielded and ventilated to protect human workers from the arc flash and fumes emanating from the work.
Key Benefits of Pre-Engineered Robotic Cells
Bringing in a robotic cell like this one has a few major benefits, which follow for not just KUKA robots and cells, but for any brand of industrial robot.
First, it greatly decreases the time needed to get up and running.
Secondly, the robot’s superior arc-on time, accuracy and repeatability will increase throughput and quality over a human-operated welding station.
Thirdly, the cell can serve as a baseline for continuous improvement programs. Operators and robot programmers can make changes to the tooling, the fixtures, and the programs to improve the cell over time.
Additionally, bringing in a pre-engineered cell is an excellent starting point for upskilling your welders for future automation projects. Contrary to popular belief, welding robots cannot yet fully replace skilled welders. Almost every industrial robot application requires a process expert to help develop the design and integration of the cell—you can’t teach a robot to do something you don’t understand yourself! With your welders assisting in improving, maintaining and working with an arc welding cell, they can gain valuable robotics skills which will serve your company well as your automation strategy develops.
We shot a similar video last year about an automotive welding cell. You can check that out here.