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Robotic applications are revolutionizing the welding industry. Not only are welding robots and associated machinery capable of handling large jobs; they can also complete tasks in an efficient, uniform manner. Robotics are increasing volume and, with properly-trained staff handling their operation, are producing results on par with the best skilled welders.
Since its charter year in 1962, John Thurston Machine Ltd. (JTM) of Brampton, Ont., has been on the cutting edge of welding technology. In 2003, a valued local client approached the diversified company with an opportunity to manufacture up to 6,000 parts, each weighing approximately 1,600 lbs. (725 kg). If JTM were to partner with this client, a Canadian division of a large U.S. company involved with defence contracts, a two-year contract, stretching perhaps into early 2006, would result.
However, as JTM Project Manager Rick Shirley explains, without robotics added to its 51,000-sq-ft. facility, JTM could not even consider taking on this mammoth project.
The part to be manufactured is the shape of a shoe-box lid, and measures 4 ft x 8 ft x 16 in., with a one inch thick top plate and ? -inch-thick sides.
“We made the first few by hand,” says Shirley. “The time to manufacture one was about two hours and 15 minutes. On the robot… we have that down to 42 minutes.” He adds, “Robotics were the difference between getting the job, and not getting the job. We were bidding against people whose business is robotics, and if you’re not in that business, you’re not going to compete”.
JTM not only acquired a state-of-the-art robotics system, and in turn the two year contract; the company also updated its day-to-day operations in a high tech fashion, becoming capable of serving new and existing clients in a more extensive and comprehensive manner.
In 1962, JTM founder Len Thurston, father of current owner and President John Thurston, began operations in a two-car garage, with a lathe, a power hacksaw and a welding machine. In 1990 JTM moved into its current modern headquarters near highways 410 and 407. JTM is a multi-disciplined custom manufacturing and industrial service centre, offering relocation, installation, transportation, repair, rebuilding, refurbishing, design and manufacturing of industrial parts and machinery.
JTM’s physical plant is 65 per cent craned. The company is ISO 9001 compliant, and all of its welders are CWB certified. Boasting a skilled, educated workforce, with many employees enjoying 20-plus years with the company, JTM includes among its staff; engineers, accountants, machinists, welders, fabricators, millwrights, riggers, mechanics and drivers. A machine shop, fabrication shop, millwrighting, rigging, and transportation area all help JTM work with clients at many levels of involvement, from managing a project to supplying parts and services on demand.
“We have been primarily a job shop “explains Shirley, “concentrating more on single and small order items. That has been our niche.” Now, with a new six-axis industrial welding robot, JTM is capable of higher production of large parts for its clients. Says Shirley. The beauty of this robot is, you always get the same product. It is absolutely uniform.”
This welding system is an example of how advanced robotics are in today’s welding world. The system, for Panasonic Factory Automation in Guelph, Ont., is one in a six-axis versatile industrial-robot series. The VRGII series features high-performance manipulators that can be used for a host of automated applications, including CO2/MAG/pulse MIG/TIG welding, air plasma cutting and material handling/machine tending. Driving the speed and performance are the advanced 64-bit RISC processors. The system has a compact design, wide working envelope, brakes that come standard on all six axes, patented offset wrist design and a control pendant with seven-inch screen and colour user-interface powered by Microsoft Windows CE.
Panasonic Senior Sales Engineer Ken Van Dyk says that simplicity and efficiency are the strengths of this complete robotics system, which includes touch sensing/tracking, a Panasonic HMII-500 Amp Pulse/CV welder, and two heavy-duty, 5,000-lb. Servo-driven positioners, all mounted on a common base with guarding
Shirley says that Praxair Canada Inc. of Mississauga, Ont., helped select the proper wire/gas combination for the new robotic application.
“Praxair said, ‘Up until now, you’ve been running 44-lb. spools; let’s get you into a program of 500-lb. drums of wire.” Then they said, “you’ve been on bottles of gas up until now; let’s go to the mini-bulk system, because the last thing you need is to be halfway through a program and run out of wire or gas,” Shirley explains.
New Age Robotics of Kitchener, Ont., an authorized distributor and integrator for Panasonic robots in Canada, put the entire system together for JTM. This included ensuring that safety measures were adhered to during implementation.
Van Dyk explains, “New safety standards were introduced in Canada in March 2003 (CSA Z434-03). These standards require that all robots and perimeter guarding have a dual-chain safety circuit. For the robot, this includes all E-stop circuits, a three-position live-man switch on the programming teach pendant, and brake releases on all axes. For the system, it includes all doors and light curtains.”
The welding system used by JTM involves the robot and two large positioners. Understanding the tolerances involved with such a large part, JTM was able to make its own tacking and drilling fixtures. Additionally, JTM manufactured a jib to hold the part in the robotic positioners. The headstock (main drive) is turned by the robot servo motor.
The indexer positioner has the size and power to rotate an 11,000-lb. (5,000-kg) part. Using the robot in welding the new product, JTM can keep tolerences within 0.06 in. without the use of spacers.
There was a learning curve involved, explains Shirley. “You don’t just press a green button and go”. However, Shirley says that, with a four-day training course spearheaded by Panasonic and a three-day, in-house training session, it was all systems go complete with product support.
The robot can work 24/7, and because it has an indexer on each side, while it is welding on one side, the operator can unload the finished part on the other side and ready it by loading a new part to be welded. When the robot has finished one part, it rotates to the other positioner, and begins welding immediately.
Shirley says output will increase from 64 pieces per week to as many as 90, which would require a second shift of workers. Currently, JTM is operating its new robotic system 10 hours each day.
JTM has come a long way from its roots in 1962, using a lathe, power hacksaw and welding machine, to a state-of-the-art robot. With JTM anticipating additional robotic-type work, the future looks bright.
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