ceid-center, faculty of technology lappeenranta … · five mobile robots machines are need working...

CEID-center, Faculty of TechnologyLappeenranta University of Technology, Finland

Intersector Welding Robot

Professor, Ph.D, Huapeng Wu

Professor, Ph.D, Heikki Handroos


Introduction• Assembly welding of ITER Vacuum Vessel is extremely complex process requiring a large number of special tools and sensors to be integrated with the robotic system.

•Commercially available robot controllers havelimited accessibility to integrate special toolsand sensors.

•Mechanical stiffness of commercially availablerobots is insufficient for carrying out machining


Introduction•Laboratory of Intelligent Machines CEID/LUT has developed advanced robot solutions for ITER VV Assembly since year 2000

•The developed robot is based on a stiff parallel kinematic structure and Industrial PC-controller providing capability of flexible interfacing to any special tool and sensor system required in assembly of VV

•Two generations of prototypes have been built in LUT


Key idea IWR (Track + mobile machining centre)


1. Carriage frame

2. Track drive unit

3. Linear drive unit

4. Rotation drive unit

5. Tip drive cylinder

6. Hexapod frame

7. Water hydraulic Hexapod

8. Output plate

IntersectorIntersector WeldWeld//CutCut RobotRobot 2nd 2nd generationgeneration prototypeprototype

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Hardware Based of Beckhoff Ethercat Industrial PC cabable for interfacing with any robotic tool or sensorsystem

Tracking motor control


Open access robot software providing all necessary functions


The 2nd generation prototype of IWR in LUT


Parallel mobile machine with full track rail for assembling– Specification of parallel robot

• Degrees of freedom : 10• Dynamic payload capacity : 6KN• Functions : Handling , welding and machining• Accuracy : <0.1mm (dynamic repeatability) • mass of robot : <1000kg• Reprogrammable , user friendly interface .


Parallel mobile machine with full track rail for assembly tasks– Splice plate handling

Parallel robot machine transports splice plate weighted more than 150kg

with a heavy duty vacuum lift .


Parallel mobile machine with track rail for assembling- Welding

Welding robot carries out welding process


Parallel mobile machine with full track rail for assembling—Machining

Parallel robot machine carries out milling process


Alternative track arrangement: simple multi track rails

Five simple track rails (line and arc) instead of full track rail .

Advantage:

Simple structure ,cheap

Easy to be assembled and dismantled inside VV.

Disadvantage :

Five mobile robots machines are need working on different track rails ;

Special device is need for transporting splice plate.


Top welding and machining position

Side welding and

machining position

Vacuum lift and splice plate

IWR robot

Welding robot

Track rail

Support beam

Trial Rig Proposal to be established in VTT/RoVIRDemonstration, development and testing of Handling, Machining, Welding, NDT etc. with all necessary sensors and tools


Vertical position - machining Top-down position - machining

Trial handling, machining and welding


Conclusions 1. By providing the required dynamic stiffness and

repeatability IWR has capabilities for carrying out welding, machining, material handing etc. for the assembly of VV. To provide sufficient productivity a multi robot system can be used.

2. The robot hardware and software is built on Beckhoff’sEthercat Industrial PC which allows free interfacing of any special tooling or sensory system.

3. R&D, demonstration and testing of all necessary robotic operations required in assembly of VV can be carried out in test rig established in VTT/RoViR centre in Tampere

ceid-center, faculty of technology lappeenranta … · five mobile robots machines are need working...

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