Heavy Duty IntellIgent MobIle WelDIng & gougIng/CuttIng CaRteSIan RobotSMWR-100
TM
& MWR-350TM
Mo
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Ro
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servorobot.com
COLORVIDEO
CAMERALASER LINESCANNER
Heavy Duty IntellIgent MobIle WelDIng & gougIng/CuttIng CaRteSIan RobotS
MWR-100TM
& MWR-350TM
overviewSERVO-ROBOT is proud to intro duce MWR-100TM and MWR-350TM, two innovative new vision assisted mobile fully programmable welding robots. These three axes robots are capable of welding on any material and joint type and they are also capable of doing automated plasma beveling and cutting. The MWR-350TM model is designed to weld in all positions. The portability of the system allows it to be brought onto large weldments such as ship stiffeners and mining equipment modules, thus reducing the need to move the part within the factory which is expensive and time consuming. The simplicity of the system allows the operator to run several systems simultaneously thus reducing the cost of operation. The integrated laser vision seam tracking system has an embedded color video camera which allows remote teaching and process monitoring thus removing the operator from the hazardous welding area.
TEACH PENDANT
REMOTE MONITORING
LASER-CAMERAAND WELDING TORCH
MWRTM ROBOT
MWRTM CONTROLLER
IDLER CARRIAGE
WELDINGPOWER SOURCE
WIRE FEEDER
MWRTM
sysTeM configuRaTion
COLORVIDEO
CAMERAColor 3D/2D scan of weld
LASER LINESCANNER
servorobot.com
ROBOTIC WELDING INSPECTION SYSTEMPOWER-SCAN
TM
COMPaCT WELD BEaD INSPECTION SYSTEMPOWER-SCAN
TMI
NS
PE
CT
IO
N
servorobot.com
COMPaCT WELD BEaD INSPECTION SYSTEM
fEaTuRES aND BENEfITS
SYSTEM DESCRIPTIONThe POWER-SCAN
TM system is composed of a 3D laser vision camera head (POWER-CAMTM
family), an industrial control
unit (POWER-BOXTM
) and a software package (WELDSURETM
) to perform the inspection of the weld bead.
• Fully integrated system with laser-camera, control unit and software.
• Very compact control unit with flexible communication interface.
• Immune to the Arc Welding processes (spatter, heat, etc.).
• Not affected by ambient lighting conditions.
• Can inspect welds of any materials.
• Very rugged laser-camera frame.
• Pressurized air flow nozzle designed to protect disposable lens against dust and fume.
• High-speed digital laser-camera allows for scanning speed up to 6 meters/minute (235 inches/minute).
• Informs the robot or PLC when a defect is detected.
• Displays the part inspection results on a user-friendly 3D graphical interface.
• Saves all the inspection data available in the on-board database.
• Checks joint fit-up.
• Measures weld shape/geometry.
• Detects weld defects.
• Allows for 100% control of the parts produced.
• Eliminates manual inspection.
POWER-BOXTM
control unit
Monitoring software package
POWER-SCANTM
– iNSPECTiON SySTEM
POWER-CAMTM
laser-camera
mounted on robot
BADGOOD
POWER-SCAN
TM
PO
WE
R-
SC
aN
TM
EaSY INTEGRaTION
Interfaces:• DIGITAL I/O• ETHERNET
TCP/IP• MODBUS
TCP
CUSTOMER PLC
Inspection results:• GO/NO GO
• Defects/types & locations
Inspection control:• Start/Stop
• Task Selection
POWER-BOXTM
CONTROL UNITROBOT CONTROLLER
EaSY CONfIGuRaTION
Select the
inspection template
corresponding to the
part configuration
Groove weld...
Fillet weld
Step 2Step 1 Step 3 Step 4
Align the laser-camera
to make sure the weld
or joint is in its field of view.
Select which
criteria needs to be
monitored and set
the acceptance/
rejection boundaries
3.0 < leg size < 4.5
Throat > 2.5
Undercut < 0.3 mm
Verify that theprofiles obtained are
good in WeldComTM’s
user-friendly
graphical interface
uSER-fRIENDLY MONITORING INTERfaCE
NetSightTM
’s 3D View screen showing a defect NetSightTM
’s detailed screen showing measurements
pOWER-CAMtM pOWER-CAM/HRtM
Fillet weld Groove weld
Leg and Size (l,r) 2 to 50 mm N.A.
Theoretical Throat 2 to 35 mm N.A.
Convexity 0 to 20 mm 0 to 20 mm
Reinforcement N.A. 0 to 20 mm
Undercut (l,r) 0 to 3 mm 0 to 3 mm
Toe Angle (l,r) 90° to 160° 90° to 180°
Mismatch/Hi-Lo N.A. 0 to 6 mm
Beta Angle 30° to 140° 140° to 200°
Face Width N.A. 2 to 55 mm
Porosity, Cracks and Spatter 0.5 to 5 mm 0.5 to 5 mm
WELD INSPECTION
N.A. - Not Applicable
Weld type
Features
COMPLETE PROCESS quaLITY aSSESMENT ThROuGh hIGh
aCCuRaCY 3D LaSER PROfILING TEChNOLOGY
SERVO-ROBOT reserves the right to change product specifications without notice. ©2013 SERVO-ROBOT Inc., All Rights Reserved. Printed in China. TPOWSC1208E011
servorobot.comSERVO-ROBOt INC.1370 HOCQUART, SAINT-BRUNO, QUEBEC, CANADA J3V 6E1TEL: +1-450-653-7868 FAX: +1-450-653-7868
VISIBLE LASER RADIATIONAVOID DIRECT
EXPOSURE TO BEAM
Class 3B - IEC 60825-1.2
AlGaInP 130 mW Max Class IIIb - CDRH
LaSER-CaMERa TEChNICaL SPECIfICaTIONS
ARC WELDS INSpECtION
pOWER-CAM pOWER-CAM/HR
Stand-off to camera 70 mm 92 mm
Close plane (Field of view) 27 mm 12.5 mm
Far plane (Field of view) 76 mm 15 mm
Depth of field 140 mm 16 mm
Average depth resolution 0.09 mm 0.025 mm
Average lateral resolution 0.05 mm 0.016 mm
Weight 475 g 500 g
Dimensions (mm) [H x W x D] 94 x 33 x 58 106 x 33 x 58
Best suited for Medium to Heavy Plate Sheet Metal
Integrated color videocamera for monitoring
3 3
• Operating temperature range: 5˚ to 40˚C (41˚F to 104˚F) • Laser : Class IIIb
JOINT INSPECTION
t-Joint Butt Joint (Square, V and Bevel Groove)
Beta Angle 30° to 140° 140° to 200°
Root Opening 0 to 6 mm 0 to 10 mm
Mismatch/Hi-Lo N.A. 0 to 6 mm
Groove Angle N.A. 30° to 90°
Bevel Angle (l,r) N.A. 15° to 45°
Joint type
Features
N.A. - Not Applicable
• Dramatic quality and productivity improvements are easily achieved compared to manual and mechanized welding.
• Mobile so automation can be brought to the workpiece.
• Remote process monitoring removes operator from welding zone.
• Precise seam tracking for consistent penetration and accurate bead placement.
• Easily integrates to any welding system.
• Automated teaching reduces setup time and increases flexibility.
• Multilayer welding.
• Welding parameters can be optimized via the teach pendant.
• The actual tracking profile is visually shown on the color touch screen of the teach pendant.
tyPICal aPPlICatIonS
Mw
r-1
00
-35
0tM
featuReS anD benefItS
SHIPbuIlDIng
RaIlRoaD
MInIng
ConStRuCtIon
4 Extremely easy to use - In less than one hour, you will be welding like a pro.
4 Robot is “sensor ready” - Seam tracking, video monitoring and GPS functions can easily be added.
4 Lightweight cartesian robot with ergonomic teach pendant provides high level of safety for the operator.
4 Perfect for welding in all positions on any type of joint.
4 Rugged robot made to survive in toughest factory environment.
4 Capable of also doing automated plasma cutting and beveling which improves joint preparation quality.
4 Modularity allows robot to be used in conjunction with hard automation arc welding machines to improve their flexibility.
WItH vISIontM SySteM
• Joint Tracking.
• Adaptive control of welding parameters based on joint geometry.
• Vision assisted robot teaching for easy path programming.
QualIty anD PRoDuCtIvIty IMPRoveMentS aRe eaSIly aCHIeveD
Vertical mobile welding robot
PoWeR geneRatIon
MobIle WelDIng RobotS teCHnICal SPeCIfICatIonS
PleaSe ContaCt uS to See HoW ouR MobIle PoRtable WelDIng RobotS Can HelP you SIMPlIfy youR WelDIng autoMatIon PRoJeCtS!
Mwr-100 Mwr-350
HArDwAreWeight 27 kg
Dimensions (excluding accessories) 504 mm Width x 380 mm Height x 351 mm Length
Lateral Axis (Y) Stroke 150 mm
Vertical Axis (Z) Stroke 150 mm
Rail Compatibility Gullco type rails
Load Carrying Capability 45 kg / Flat and horizontal only 160 kg / All positions
Maximum Load on the Y and Z Axes 25 kg
Maximum Travel Speed 2.5 m/minute
Maximum Cable Length 30 m
Torch HolderManually adjustable lead/lag and work angles
– Lead/lag angle: +70 /-15 degrees– Work angle: +/- 15 degrees
Optional Idler Carriage for Wire Feeder and Wire Spool Yes. Can be pulled or pushed
control unit cHArActeristicsDimensions 500 mm Width x 500 mm Height x 200 mm Depth
Weight 27kg
Weaving
Triangular weaveProgrammable width and frequency
3 programmable dwell times: left, center, rightY axis only or perpendicular to the torch axis
Welding Power Source Control Ethernet link for ArcLink™ interface; Analog and Digital I/O (up to 4 control signals) Complete control of the welding process, including voltage, wire feed speed / current, gas, burn back and crater fill
Robot Programming Method Teach & Play programming method with user friendly graphical interface
Path Control Linear interpolation between taught points
Programs Up to 10 programs and 100 positions with welding parameters in each program
Power Failure Protection Automatic configuration recovery after a power failure
Pause/Restart Support Automatic restart after a pause or emergency stop
teAcH penDAnt coMMon cHArActeristicsConnection Can be connected to the robot or the control unit
Display Color touch screen
Safety Emergency stop push button
Backup USB port for program and configuration backup
Monitoring Real-time display of the welding parameters
Cable Standard 2 meters (other length available)
SERVO-ROBOT reserves the right to change product specifications without notice. ©2013 SERVO-ROBOT Inc., All Rights Reserved. Printed in China. TMWRVS1308E01
servo-roBot inc. 1370 Hocquart, St-Bruno Quebec, CANADA J3V 6E1Tel.: +1-450-653-7868Fax: +1-450-653-7869
COMPLETE SOLUTION FOR JOINT TRACKING AND ADAPTIVE PROCESS CONTROL DESIGNED FOR SPECIAL WELDING MACHINES
AUTO-TRAC/ITTM
ARC
WEL
DING
servorobot.com
• Fully integrated standard system with laser-camera, control unit, actuators, teach pendant and software.
• Large selection of laser-sensors available to support specific processes and joint types.
• Immune to the Arc and Laser processes (spatter, heat, etc.).
• Not affected by ambient lighting conditions.
• Can track on any weldable materials including aluminum.
• Pressurized air flow protects disposable lens against dust and fume.
• High speed digital laser-sensor allows for fast and reliable joint recognition.
• Extensive to use with all industrial joint preparations.
• Automatic joint recognition.
• With the use of the teach pendant, the axes position can be taught the same way as a robot.
• Adaptive process control firmware interface directly with the welding equipment.
• High speed, high accuracy rugged actuators for precise torch positioning.
COMPLETE SOLUTION FOR JOINT TRACKING AND ADAPTIVE PROCESS CONTROL DESIGNED FOR SPECIAL WELDING MACHINES
AUTO-TRAC/ITTM
FEATURES AND BENEFITS
AUTO-TRAC/ITTM
SYSTEM
ROBONET/MASTERTM
ROBONET/DRIVETM
GROUND FAULT VIDEO SCREEN
WELDCOMTM HMI
CUSTOMER PLC
LASER-SENSOR
INTERNET
FACTORY AIR IN
VIDEO CABLE
TEACH PENDANT
INTE
RNET
CAN
-OPE
N
SAFETY LINKS
LASER-SENSOR CABLE AIR
HOSES
ETHERNET
COOLING CONTROL
Z ACTUATOR (Drive and Encoder)
I/O OR FIELDBUS
X-Z ACTUATORS
ENCODER
COOLING UNIT
AIR FILTER KIT
TEACH PENDANT
Y ACTUATOR (Drive and Encoder)
X AXIS ENCODER
TYPICAL APPLICATIONS• Fuel Tanks
• Pressure Vessels
• Bridges Structures
• Shipbuilding
• Wind Tower Turbines
• Water Heater Tanks
• Railway Car
• Pipe (Spiral and UO pipe)
EXCLUSIVE FUNCTIONSAUTO-TRAC/ITTM is available for any joint preparation ranging from sheet metal tight butts to heavy plate complex grooves.
The system drives motors with encoders thus providing in real time the current position of the welding torch in space. This provides to the system the possibility to be taught like a robot.
In addition, the encoders allow one to generate the proper trajectory while tracking, taking into account the travel speed, the position of the camera related to the torch and the current positions of the torch. The end result is a good weld that meets the most stringent quality requirements.
The presence of encoders allows memorization of the joint trajectory which is a very useful tool to evaluate the part deviation that can be played back in multipass welding application. This also allows to monitor the part preparation to improve the quality.
AUTO
-TRAC
/ITTM
ROBONET/DRIVETM brushless servo driver
High-speed actuators (See complementary document)
ROBONET/MASTERTM process control unit
EASY OPERATIONOperation is made by the operator or by the PLC through an I/O interface. The operator uses the teach pendant to set-up and select the sequence, perform calibration and jog axes. In addition, the teach pendant always provides the system status to the operator. With the teach pendant, the axes position can be taught the same way as a robot.
Teach pendant
AUTO-TRAC/IT TM CONTROLLERSThe AUTO-TRAC/ITTM main controller is the ROBONET/MASTERTM. It is a powerful processing unit that manages the system sequence, the laser-camera profiles processing, the trajectory computation and the process adaptive control. A CAN-Open interface links it to the ROBONET/DRIVETM controller which is driving the axes. Up to 3 axes can be driven and a fourth one such as a positioner, roller or gantry can be read.
The system offers various possibilities to be interfaced with PLC’s and different welding power sources through Digital I/O, analog signals or field bus.
Taught Points
Laser-sensor finding and action
Laser-Camera
Servo-Robot reserves the right to change product specifications without notice. ©2011 Servo-Robot Inc., All Rights Reserved. Printed in Canada. TAUTTR0618E05.2
[email protected] servorobot.com
LASER-CAMERAS TECHNICAL SPECIFICATIONS
ARC WELDING LASER WELDING
DIGI-I/S MINI-I/D QUANTA/SP QUANTA/SP-350 QUANTA QUANTA/LFStand-Off from nozzle 5.6 mm 5.5 mm 47.5 mm 93.9 mm 98.8 mm 93.8 mm
Close plane (Field of view) 23 mm 27 mm 48 mm 66 mm 8.1 mm 15.6 mm
Far plane (Field of view) 45 mm 76 mm 88 mm 194 mm 8.6 mm 17.6 mm
Depth of field 65 mm 140 mm 120 mm 350 mm 6.5 mm 16 mmAverage depth resolution 0.075 mm 0.09 mm 0.05 mm 0.23 mm 0.008 mm 0.015 mm
Average lateral resolution 0.035 mm 0.05 mm 0.07 mm 0.13 mm 0.009 mm 0.017 mm
Weight 600 g 475 g 800 g 800 g 800 g 800 gDimensions (mm) 113 x 62 x 34 108.1 x 58 x 33.3 113 x 145 x 40 113 x 145 x 40 113 x 145 x 40 113 x 145 x 40
Best Suited For Sheet Metal Heavy Plate Heavy Plate Very Heavy Plate (Pressure Vessels)
Tailored Welded Blanks TIG Welding
• Environment : 5˚ to 40˚C (41˚F to 104˚F) • Laser : Class IIIb
MINI-I/DTMDIGI-I/STM QUANTA/LFTMQUANTATMQUANTA/SPTM QUANTA/SP-350TM
TRACKING AND MONITORING SYSTEMSIN ONE PRDUCT!