robotic spot welding guns

ARO Welding Technologies

ROBOTIC SPOT WELDING GUNS

3G : Global Gun Generation


Customer Needs in Robotic Welding

Reduce Total Cost of Ownership

Reduce up front project costs (capital investments)

Increase line up time : Reliability & Maintainability

Reduce Spare Parts / Standardize

Increase gun performance for new materials

Have a World Compatible design

Increase Flexibility of the BIW production line

Reduce Design Time, Delivery Time, and Diversity


ARO is addressing these Needs with a new Break Through Design relying on :

ModularitySimplicityRobustnessHigh Performance

Customer Needs in Robotic Welding


TECHNICAL CONCEPTS

OPTIONAL EQUALIZING

“NON ISO” WELDING TRANSFORMERS

“SMOOTH ROD” SERVO-ACTUATOR

SINGLE FACE MOUNTING (S2M Concept)

GLOBAL HOUSING / EXACT MODELLING

SINGLE X & C GUN FRAME

LOW CUSTOMISATION PRODUCT


DESIGN CONCEPT

Use a Side Plate

Strong

Universal


Mount 4 Modules1. Transformer

2. Shunt Adapter

3. Fixed Arm Compliance Shunt

4. Fixed Arm Holder

DESIGN CONCEPT


Assemble a Universal Basic Gun Body

5 Components

20 Minutes

Slide in Transformer

DESIGN CONCEPT


DESIGN CONCEPT

1. In Line Servo Actuator

2. Pivot Module

3. Mobile Arm Adapter

4. Multi Function Flexible Shunt

5. Stiffening Link

Take 5 more Modules


You Have an X Gun Body

5 Modules

OR…

DESIGN CONCEPT


Use the Universal Basic Gun Body

DESIGN CONCEPT


DESIGN CONCEPT

Take 3 more Modules

1. In Line Servo Actuator

2. Mobile Arm

3. Multi Function Flexible Shunt


You Have a C Gun Body

3 Modules

15 Minutes

DESIGN CONCEPT


Plug in Arms and Inspect

DESIGN CONCEPT


DESIGN CONCEPT

The Gun is Complete – We Have Used :

Less than 15 Modules

Less than 40 ScrewsOnly 3 Tools

MTTR < 10 Minutes


4 Modules

You also can make an Aluminum arm gun (3GZ)

DESIGN CONCEPT


One Last Item: Attach Gun Cover!

3 Minutes

DESIGN CONCEPT


LOW CUSTOMIZATION LEVEL

Plant Consumables

Power and Control

Connectors


10

11

12

13

14

15

16

Stiffening link for X guns

Flexible shunts for all guns

Compliance shunt for copper guns

C gun moving arm

Side plate for all guns

Shunt adapter for moving Alu arm

Shunt adapter for copper X gun moving arm

Less than 10 other small parts(such as fittings, O ring,..)

1

1

2 2

3

4

5

6

78

9

10

11

11 12

13

14 14

14

15 16

List of ALL spare components for ALL 3 gun bodies!

17

MFDC Transformer

Servo for X guns

Servo for C gun

Pivot module for copper X guns

Pivot module for Alu X Guns

Arm holder for Copper C and X guns

Arm holder for Alu X Gun

Shunt adapter module for copper guns

Shunt adapter module for Alu X gun

1

2

3

4

5

6

7

8

9


Do You Need a Gun Equalizing Function?

Independent Servo Adaptive Module

(pneumatic also available)

DESIGN CONCEPT


3G X(CuCoBe Ø 54mm)

3G Z(Aluminum arm

90x40)

0

100

200

300

400

500

600

700

800

900

1000

1100

0 100 200 300 400 500 600 700 800 900 1000

Wel

ding

forc

e (d

aN)

Arm length (mm)

Welding Force vs. Arm Length

3G C

RW

HIGH PERFORMANCE FOR NEW HSS


INCREASE LINE « UP-TIME »

3 Gun body variation made out of :

9 shared modules

+ 7 specific modules

+ 2 plug and play arms

Covers 95% of Body in White needs

16 Modules in total

Less than 40 Screws/gun

Only 3 Tools

Highest reliability

MTTR < 10 minutes


Gun is fully covered to protect from contamination

No need for expensive gun bags

Less failures

Easier maintenance

Exact 3D Model

DESIGN CONCEPT


DECREASE CAPITAL INVESTMENTS

Through considerable innovation, ARO is setting a new reference

Low investment in spare guns

Low expense for initial spare parts

The dramatic improvement of the ARO design in simplicity, standardization and MTTR allows for considering an operation without spare guns.

The standardization allows for fewer spare parts


DECREASE RUNNING COSTS

Less spare parts, cross references, inventory spaceDramatic reduction of component diversity substantial reduction in number of spare parts / spare modules

This also impacts the cost of managing parts diversity (storage space, cross referencing,...)

No in house repair / less specialized workforceThe simplicity, absence of hoses, single side mounting and optimized modularity allow for much easier trouble shooting, repair and maintenance

Concept relying on replacing modules eliminates the need to have costly in house repair areas


Environment friendly => less water

Current MFDC gun 3G ARO MFDC gun

Transformer Water flow requirement =

7.5 L / min

Transformer Water flow requirement =

4 L / min

Estimated consumption in one day for 300 guns (transformer has to be on a parallel loop)

1 400 000 Gallons

Estimated consumption in one day for 300 guns (transformer is in series with one arm)

800 000 GallonsSaves ~ $15,000/year in electricity to pump


REDUCE GUN ARMS DEFLECTION


Reduce Spare Parts/ Standardization

50% to 60% less parts than conventional gun design

~ 50% Common parts among gun types (C, X, Aluminum Arms)

Patented Universal Side plate platform


World Compatible design of the gun bodies Global Flexibility

No BSP or NPT fittingsworldwide implementation is easytransferability of tools is easy

Metric standard fasteners

Same basic body for C gun, mediumcopper and large Aluminum X gun

less costly and faster late design changes


Increase Flexibility

Gun body can be converted from C to X or from copper arms to Aluminum arms just by swapping a few modules.

Arms are plug and play and can be adapted to any application without touching the gun body


Can be added only if and when needed

Independent Servo Adaptive Module

(pneumatic also available)

PATENTED OPTIONAL EQUALIZING


Reduce Design Time and Diversity

The full cover defines precisely the 3D model. There is no surprise when installing the gun on the line.

The cooling circuit is integral to the components when they are being assembled. It is clean, repeatable and is not subject to the creativity of the pipe fitters.

When the gun is assembled, it is also completely dressed.

DocOnline – Gun Drawing View


GLOBAL GUN GENERATION

Summary


STANDARD OFFER

ARMSET

SUPPORT 0 or 90° or 180°

X or C w/o Equalizing

SERVO ACTUATOR

TRANSFORMER


STANDARD CONFIGURATION

STANDARD OPTIONALX GUNC GUNSERVO ACTUATOR- With resolver- With encoder- With Brake- With Force SensorPNEU CYLINDERTransfo ACTransfo MFDCEqualizing Pneu.Equalizing Elect.ArmsetSupport 0 or 90°Tool ChangerSymetrical gun


ACHIEVEMENTS & BENEFITS

No spare guns Possible

Spare parts - 60%

Reliability & Maintainability + 100%

Optional EQ Yes

Less in house repair Yes

Global / Flexible Yes

Exact 3D models Yes

Short & Reliable delivery time Yes


BREAK-THROUGH DESIGN

ARO’s unequalled modular and servo gun expertise3 years of R&DHeavy investments in ToolingSeveral Patents

Simple, Robust, Flexible, Global

robotic spot welding guns

Documents