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KUKA welding robot at ENKO Staudinger

ENKO Staudinger combines various welding processes in a compact universal cell

Augsburg-based ENKO Staudinger GmbH specializes in the development, design and manufacture of tools, fixtures, special machines and machine tools

With more than 40 years of experience and know-how, around 70 employees manufacture both conventional, manual fixtures and individual, complex systems for customers in the automotive industry, aerospace industry, chemical industry and general industry

Robotic solutions for a combined welding cell

For Denkingen-based KAUTH GmbH und Co. KG, a company that specializes in highquality metal processing, ENKO Staudinger has developed a compact universal welding cell, combining a range of different welding processes in a single cell with minimized space requirements. “The requirement of the customer Kauth was the construction of a welding cell that was suitable for both spot welding and arc welding, taking all accessibility requirements into consideration,” explains Bernd Menhart from ENKO Staudinger. The Augsburg-based manufacturer built the cell around two KUKA robots that perform the welding tasks.

Rotating table allows loading with no effect on the cycle time

The universal cell is centered on an H table with a KUKA robot of type KR 6-2 mounted in the middle. Use of a rotating table means that there is always one welding fixture in the productive process, while the second fixture is being loaded by the operator with no effect on the cycle time.

First of all, an operator loads the workpieces into the welding fixture and starts the system. The table rotates the clamped fixture through 180° beneath the robot into its welding area. The KUKA KR 6-2, equipped with a Fronius CMT torch for arc welding, moves into the fixture and welds the workpieces. A second robot, of type KR 210 R2700 extra, equipped with an X 100 servo-pneumatic robotic gun from Düring Schweißtechnik, then moves into the fixture again and joins the workpieces by means of spot welding.

On completion of the welding process, the H table rotates and a second, newly loaded fixture enters the workspace of the robot. The rotation of the table moves the first fixture back into the workspace of the operator. The clamps open pneumatically and the operator can remove the welded parts. The loading/unloading by the operator has no effect on the cycle time.

Two robots combine mobility with precision and speed

With its low payload capacity of six kilos and a reach of 1,600 mm, the KUKA robot of type KR 6-2 mounted on the table is ideally suited to standard arc welding tasks. The streamlined design of the wrist ensures that the robot enjoys minimal disruptive contours and maximum freedom of motion. The welding expert is thus able to reach all welding positions on the workpiece effortlessly.

The KR 210 R2700 extra performs spot welding tasks with high precision and at high speed. As is the case for all robots in the KR QUANTEC series, it is characterized by reduced space requirements and a wide variety of potential applications. With a payload capacity of 210 kg and a reach of 2,926 mm, it is predestined for the spot welding process in the universal cell. 

The KR 6-2 (on the right) performs the arc welding while the KR 210 guides the servo-pneumatic robotic gun

Highly flexible solution for frequently changing tasks

The cell provides the customer with a wide range of options for the universal implementation of various welding processes, or even combination with other robotic tasks. This flexibility makes the solution of particular interest for small series and prototype production, as the cell can be adapted very quickly and easily to new workpieces.

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