panasonicfactory solutions company technology · where welding and robot technologies merge...

where welding and robot technologies mergePanasonic Factory Solutions Company introduces TAWERSTM, The Arc Welding Robotic Solution. TAWERS is a fusion of robot and welding technologies utilizing EACTM (Embedded Arc Control) Technology. TAWERS is a revolution in technology built on decades of industry-leading production experience.

EAC Technology: Eliminating barriers…opening opportunities TAWERS comes standard with Embedded Arc Control (EAC) technology which eliminates the need forthree separate control systems and fuses control of the robot, welder and servo wire feeder into a singlephysical unit. This new controls breakthrough is contained entirely internal to the robot controller and ismonitored by the TAWERS 64-bit main CPU. EAC technology controls not only the robot motion path andsequence commands, but simultaneously synchronizes the welding power supply waveform control andservo wire feeder response accordingly, to adjust and correct for dynamic changes in the welding process.TAWERS with EAC technology soars beyond conventional digital communication systems, delivering thefirst generation of fully software-controlled robotic welding solutions.

We invite you to learn more about the TAWERS EAC Technology advantage…and discover how thisrevolutionary solution provides greater welding flexibility, ultra low spatter, and higher quality welds fordramatically increased productivity.

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Panasonic Factory Solutions Company knows the challenges themanufacturing industry faces. We’ve developed world-class roboticarc welding solutions that help you outperform your competitionaround the corner and around the world. We are Panasonic, theexperts in welding productivity—providing innovative technologiesfor today’s manufacturing leaders.

300mm 4- 18mm

4- 12mm H7

4H7 Depth 1045 deg ± 0.1

22.5 deg ± 0.1

4-M5x0.8 Depth 8

on 50mm diameter

4-M6x1 Depth 12on 50mm diameter

40H7 Depth 4.4mm

Robot Base

TA Robot Wrist

TA Work Envelope

Point P

Pt PPoint P

D: WaistRadius

B: MaximumReach

A: MinimumReach

C: WorkingRange

Panasonic Factory Solutions Company1-888-PANWELDPFSAmarketing@us.panasonic.comwww.panasonicfa.com

experts in productivityPanasonic Factory Solutions Company

North American HeadquartersPanasonic Factory Solutions Company 909 Asbury Drive Buffalo Grove, IL 60089 1-888-PANWELD

Satellite OfficesPanasonic Factory Solutions Company3026 Owen Drive, Suite 106 Antioch, TN 37013615-741-7111

Panasonic Factory Solutions Company20608 Madrona Avenue Torrance, CA 90503310-783-4878

Related CompanyPanasonic Canada Limited430 Laird Rd, Unit 1 RR#6 Guelph, ON N1G 3X7, Canada 519-780-2161

*Consult Panasonic for TB Robot Technical Specifications

W001.04

Panasonic Factory Solutions Company

FEATURING Embedded Arc Control TECHNOLOGYFEATURING Embedded Arc Control TECHNOLOGY

TA Robot Technical Specifications

TA1000 / TA1400 / TB1400* TA1600 / TA1800 / TA1900 / TB1800*

Axes 6 6

Payload (kg) 6 8 / 8 / 6

A: Min. Reach (mm) 362 / 352 360 / 472 / 552

B: Max. Reach (mm) 1068 / 1374 1598 / 1796 / 1895

C: Working Range (mm) 706 / 1022 1238 / 1324 / 1343

D: Waist Radius (mm) 275 290

Repeatability (mm) +/- 0.1 +/- 0.1

Manipulator Weight (kg) 145 / 161 180 / 185 / 185

Mechanical Brakes All Axis (Release switches on robot)

Mounting F C W A / F C A F C A

RT 340 340

UA 245 255

FA 305 / 350 475

RW 540 540

BW 240 255

TW 800 800

RT 170 170

UA 190 170

FA 190 175

RW 370 360

BW 375 350

TW 600 540

RW 164 240 / 240 / 150

BW 164 240 / 240 / 150

TW 54 100 / 100 / 60

RW 4.3 7.3 / 7.3 / 3.8

BW 4.6 7.3 / 7.3 / 3.8

TW 0.5 1.3 / 1.3 / 0.6

Controller/Welder Technical Specifications

Input Power 3 Phase 200VAC +/- 20VAC,23kVA 50/60Hz

Duty Cycle 350A 80% CV,350A 60% Pulse

Output Current Range 30–350 ADC

Output Voltage Range 12–36 VDC

Max No Load Voltage 65 VDC

Cooling Method Indirect Air Circulation

IP Rating IP 22

Welding Method Pulse, CV(SP-MAG)

Wire Types Mild Steel, Stainless Steel

Wire Diameters 035–045" (0.9–1.2 mm)

Weight (kg) 110

Wire Feeder Technical Specifications

Motor Type 50W AC Digital Servo

Weight (kg) 3

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300mm 4- 18mm

4- 12mm H7

4H7 Depth 1045 deg ± 0.1

22.5 deg ± 0.1

4-M5x0.8 Depth 8

on 50mm diameter

40H7 Depth 4.4mm

Robot Base

TA Robot Wrist

TA Work Envelope

Point P

Pt PPoint P

D: WaistRadius

B: MaximumReach

A: MinimumReach

C: WorkingRange

*Consult Panasonic for TB Robot Technical SpecificationsG

W001.04

TMTA Robot Technical Specifications

TA1000 / TA1400 / TB1400* TA1600 / TA1800 / TA1900 / TB1800*

Axes 6 6

Payload (kg) 6 8 / 8 / 6

A: Min. Reach (mm) 362 / 352 360 / 472 / 552

B: Max. Reach (mm) 1068 / 1374 1598 / 1796 / 1895

RT 340 340

UA 245 255

FA 305 / 350 475

RW 540 540

BW 240 255

TW 800 800

RT 170 170

UA 190 170

FA 190 175

RW 370 360

BW 375 350

TW 600 540

RW 164 240 / 240 / 150

BW 164 240 / 240 / 150

TW 54 100 / 100 / 60

RW 4.3 7.3 / 7.3 / 3.8

BW 4.6 7.3 / 7.3 / 3.8

TW 0.5 1.3 / 1.3 / 0.6

IP Rating IP 22

Weight (kg) 110

Weight (kg) 3

advance to the next level

The 64 bit TAWERSTM robot and welder share a common control platform—utilizing EACTM technology—with a new interfacethat operates 140–250X faster than conventional systems and blurs the line between welding and robot control. Theseadvances offer remarkable new high performance Pulse and CV (SP-MAG) welding solutions.

automatic stickout correctionThis valuable optional software feature increases welding process control by allowing the robot to correct for stickoutvariation due to errors in robot path programming. The robot corrects to a pre-programmed electrical stickout definedby the technician on either a per weld or global basis. This correction eliminates a variable from the welding processproviding more consistent penetration while reducing the chances for burn through.

robot lift arc startingAs the robot senses current detection it retracts to create the welding arc using voltage instead of current—dramaticallylimiting ignition spatter common to CV and Pulse welding processes. The extremely fast reaction also significantly increasesfirst strike arc start efficiency.

robot lift arc endingThe TAWERS robot virtually eliminates wire stick detection time and wire burn back time by automatically lifting the wireout of the puddle during the weld crater process and proceeding to the next weld in one motion. The lift motion, not onlysignificantly reduces the total arc ending time and programming time but as a secondary benefit sharpens the weldingwire simultaneously, thus maximizing the starting success of the next weld.

arc data monitorA high resolution arc data monitoring system whose effectiveness is enhanced by virtue of the superb stability of the wirefeed and arc control is designed into every TAWERS robotic arc welding solution. As part of the standard package, thesystem can monitor specific control limits set for a variety of macro and micro welding parameters and signal when thewelding process is not within the preset limits. Two optional software packages exist to take monitoring to the next level.The first package offers the ability to perform data logging of actual and preset welding parameters while correlating these

values to the points within the welding program. This log is then stored for later analysis and or export.

The second package offers the user an oscilloscope function, resident on the robot teachpendant, with the ability to display high sampling rate data in a high resolution format fordetailed waveform analysis by a welding engineer or lower resolution for production qualitycontrol. There is no longer a need to drag sensors and computers out to the welding shopfloor—with TAWERS the high resolution arc data monitoring hardware is standard. Takeyour welding process control and analysis to the next level with TAWERS, the arc weldingrobotic solution.

TAWERSTM welder:breakthrough capabilities in a compact package

TAWERSTM bus communication:

revolutionary welding process SP-MAGSP-MAG is a new welding process developed out of industryneeds for a more versatile CV welding process. Where conven-tional and even high-end CV processes have tried to producelow-spatter, high-speed welds—they have missed the markultimately demanding lower amperage levels or slower weldingspeeds to achieve their goals. TAWERS has successfully metthese challenges by bringing together the major benefits ofPulse and CV into one process SP-MAG…

• Ultra low spatter levels

• Low heat input

• Low susceptibility to arc blow

• Wide process windows across entire amperage range

• Excellent thin material and gap handling capability

ultra low spatter process SP-MAGSpatter is the enemy of every company, big or small. TheTAWERS solution takes aim at not only the arc physics thatgenerate spatter, but also other factors that directly impactspatter generation. SP-MAG combined with advances inwelding arc starting and ending have led to an extremedecrease in the amount of spatter generated during the entirewelding process. Extensive testing has shown that a switchfrom conventional CV to SP-MAG could result in a savings of…

• 100–150 lbs of less spatter generated per arc(200A, 60% arc on, 80% eff, 1 shift 240 days/yr)

• 100–150 lbs less wire purchased per arc

• Reduced or eliminated secondary cleanup operationssaving manpower, floor space and limiting total workin process

ground-breaking feedback controlUsing a 100 kHz primary side high frequency inverter, TAWERSoffers an extremely fast response—providing exceptionallyprecise, almost real time, control of the welding arc.

• 10-5 sec (10 micro second) control and correction cycle

• 5X faster response than conventional feedbackcontrol circuits

• Electronic reactor control makes special process inductancetaps a thing of the past. Optimum current control during allphases of welding is now possible.

• Ability to change at will between pulse and CV duringwelding means no performance compromise and superiorgap handling while maintaining wide process windowsduring low- or high-speed welding.

dust-proof sealed robot and welderTAWERS incorporates a highly sophisticated coolingsystem that evacuates heat from the welder section,eliminating the need to circulate outside air across vitalelectronic components.

• Virtually eliminates failures due to welding particlecontamination

• Provides a more efficient, maintenance-free design

• Increases uptime and reliability

• Fan on demand cooling system to reduceenergy consumption

The information provided within this document is subject to changeat any time without notice.

The 64 bit TAWERSTM robotic welding solution control platform is designed to increase your welding quality while boosting yourproduction capabilities with exciting new technologies.

optimized for productivityTAWERSTM arc welding robots are the culmination of yearsof research combining the new line of high performance TAseries manipulators with the latest generation WG weldersfused together using EACTM technology. The next generationin robotic welding solutions is offered in a broad range ofmodels to maximize your productivity through world classadvancements unique to the TAWERS platform.

TAWERS robots are optimized for speed—with larger motorsand drives, increased acceleration and a high rigidity FEAoptimized design. Exceptionally high maximum robot speedsmaximize your performance by driving down cycle times.

These advances combined with innovative robot weldercommunication, industry leading welding technologiesand effective software and hardware improvements createpowerful new solutions for your arc welding challenges.

reduced and integrated cablingThe ability to design and manufacture the robot, welder andfeeder package by the single equipment manufacturer providesflexibility of design, eliminating compromises required by multiplevendor solutions. TAWERS capitalized on this design flexibilityresulting in an extremely clean and compact feeder and cablingpackage. Innovative cable management and design innovationsprovide additional tangible benefits including…

• Decreasing dynamic stresses which allow better accelerationand higher speeds

• Practically eliminating routine feeder and cable maintenance

• Internal feeder cable management which increases uptimeby eliminating downtime

advanced awarenessThe TAWERS robot control platform incorporates intelligentcollision detection software that monitors the force appliedto the robot arm and drops into a soft servo mode when anabnormal force is detected. This function greatly reduces pin-ning of the torch against the welding fixture or positioningdevice—a common problem in competitive designs that dropinto an emergency stop condition at abnormal force detection.

servo feeder on boardDuring production one of the most important factors in asuccessful welding process is feedability. For this reason everyTAWERS robot comes standard with an AC digital servo wirefeeder. This new wire feeder not only provides a clean andcompact package but just as importantly, it provides…

• Strong, steady wire feeding with exceptional performancein low or high load situations

• Highly controlled acceleration/deceleration synchronizedwith the robot through bus communication for optimumstart, weld and ending performance

• Extremely high level of instantaneous wire feed consistencyproviding an unprecedented level of arc length control

increased control over the welding processAn optional software package, WPMGR (Welding ProcessManager) was developed based on a high volume automotivemanufacturer’s need to go beyond standard password protection.Total management control requires that there be limited accessto the welding process based on an employee’s training, capa-bility and/or authorization level to modify specific areas of thewelding program. WPMGR divides the welding process into sixaccess levels and allows registration of up to 20 supervisorswith the ability to allow or restrict access to each of these levels.The levels include…

• Welding conditions such as amps, volts, travel speeds, etc.

• Welding positional editing (X, Y, Z)

• Addition, deletion or editing of welding points

• Welding torch angle editing (U, V, W)

• System setting control parameters

• Master access level

• The system also performs a data log to track access tothe system by supervisor, access code type and time.

TAWERSTM robot series*

7 models available: from 1000mm to 1900mm reach

*Please see your Panasonic distributor or representative for complete details.

TAWERS AL MIG• High-performance

push-pull aluminumfeeding

• Syncro-weaving function

• Lift-start• High-speed welding• Converts in minutes

TAWERS TIG• High-speed TIG• Lift-start• Adapts to all

TAWERS TA Arms• DC Current: steel/

stainless• Converts in minutes

TAWERS TB ARM*• TA1400 and TA1800

arm available • Torch through arm• Slim wrist• Dual robot

applications• Inside box welding

applications

• Low heat input

applications

• Low heat input

applications

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300mm 4- 18mm

4- 12mm H7

4H7 Depth 1045 deg ± 0.1

22.5 deg ± 0.1

4-M5x0.8 Depth 8

on 50mm diameter

40H7 Depth 4.4mm

Robot Base

TA Robot Wrist

TA Work Envelope

Point P

Pt PPoint P

D: WaistRadius

B: MaximumReach

A: MinimumReach

C: WorkingRange

*Consult Panasonic for TB Robot Technical Specifications

W001.04

TA Robot Technical Specifications

TA1000 / TA1400 / TB1400* TA1600 / TA1800 / TA1900 / TB1800*

Axes 6 6

Payload (kg) 6 8 / 8 / 6

A: Min. Reach (mm) 362 / 352 360 / 472 / 552

B: Max. Reach (mm) 1068 / 1374 1598 / 1796 / 1895

RT 340 340

UA 245 255

FA 305 / 350 475

RW 540 540

BW 240 255

TW 800 800

RT 170 170

UA 190 170

FA 190 175

RW 370 360

BW 375 350

TW 600 540

RW 164 240 / 240 / 150

BW 164 240 / 240 / 150

TW 54 100 / 100 / 60

RW 4.3 7.3 / 7.3 / 3.8

BW 4.6 7.3 / 7.3 / 3.8

TW 0.5 1.3 / 1.3 / 0.6

IP Rating IP 22

Weight (kg) 110

Weight (kg) 3

panasonicfactory solutions company technology · where welding and robot technologies merge...

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