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igm Robotersysteme
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  • Offer Profile
  • igm - unique welding solutions worldwide

    igm offers complex customized solutions for automated welding and cutting processes. The product variety for individual applications in the area of robot welding technology is unique throughout the world.

    With over 30 years experience in the development of welding robots and in the planning of customer-specific welding production units, we offer an extensive range of system modules.

Product Portfolio
  • Robots

      • The new RTE 400 series

      • Mechanical components newly available on the market, a series of our own new system modules, and the demands of many customers for a bigger work zone prompted the planning of a production series of welding robots comprising several different modules.

        Perfect arc welding

        igm robots - 6, 7 or 8 rotary axes in a solid aluminum cast construction to be mounted either upright or in suspended position - are especially designed for arc welding.

        • New modules like rotating base and rotation axis in first swivel arm, robots with 6, 7 or 8 axis are available.
        • Optimal set up of all system components permits a reduction in transfer time by up to 30% for all construction sizes.
        • 1 or 2 wire feed units together with all hose package connections and media supply lines have been integrated in the main rotation axis. Accordingly, all the gas and water supply hoses as well as all the wire guides for single-wire and tandem welding are located inside the housing.

        All the advantages typical of igm robots have been retained in full:
         
        • Outstanding programming techniques with both the K6 programming teach pendant and the offline teaching system.
        • Large work zone and perfect welding access to seam positions due to an optimal axial geometry and holding of the welding torch in the wrist axis, implemented as a hollow shaft.
        • The torch and the hose packet are interchangeable by means of a clamping device in the robot's hollow wrist shaft.
        • All cables are inside the robot arms using hollow shafts.
      • igm RTE 499 welding robot - Rotating base - integration as 7th robot axis

      • The working radii of igm welding robots are between 1500 mm and 1900 mm, depending on type. This is the length of the swivel arms (550 mm or 750 mm each) plus the usual eccentricity of the first main axis, 400 mm. Extending this by lengthening the arm isn't always effective, since both reach and accessibility are essential when welding complex work pieces.

        The ability to plunge inside the component is therefore a significant criterion. Long robot arms obstruct such movements since they make large compensatory movements over external travel axes necessary. Improved movement is always achieved when more axes are used.

        The priorities are accessibility, reach-over of components, the joining crashing and overlapping of working ranges by multiple robots in one system. Additional priorities include the prevention of compensatory travel over floor track systems, i.e. shorter floor track systems. This also results in significant space savings, smaller footprint and thus lower investment costs.

        Since the rotating base can swivel ± 180°, any number of positions within working range can be approached from different directions. When using 2 robots on one station, the additional axes enable the dangers of collision to be more easily prevented. This means that both robots can weld seams which are in close proximity, or even that their working ranges overlap. For example, one of the robots is able to weld the inside of a U-shaped component, whilst the other is welding the outside.

        Features
        Significant features of the RTE 499:
        • Diameter of area of movement: 5,200 mm
        • Curved rotating base to reach around interfering contours of the workpiece
        • All media (power, water, wire, sensor cables control cables) are passed through the rotating base
        • Swivel range ± 180°
        • Fully integrated in the control system as 7th axis
      • Summary of technical robot data

      • Mechanical Features
        Weight                                                            ca. 275 kg (without welding equipment)
        Nominal payload on wrist joint                 10 kg
        collision detection                                        Electronic collision sensor, integrated into wrist joint

        Media transmission
        Welding current                                            Special transfer unit inside of robot axis 1
        Cooling system                                            Cooling water circuit up to gas nozzle of torch
        Cable                                                              guiding Inside, protected

        Motor
        Type of motors                                              Maintenance-free AC servo motors with brakes
        Measuring system                                       resolver

      • Media Transmission in the Robot Base

        • All air lines, welding cables, control lines as well as the welding wire are led through the robot base.
        • No hoses or lines run outside the robot base (excepting hose package and camera cable). This means: No looping around the work piece or other objects
        • Simplified plunging into a work piece, since there are no external cables.

        Integrated Wire Feed

        • Extremely flat design
        • Integrated in the front axis
        • Protected by cover
        • Wire guide in the axis
        • No exposed hoses
        • For single-wire and tandem welding processes
        • Fully accessible manual control push-buttons
        • Hinged medium plate
        • New central connection with quick-release coupling
        • Integrated electrical wiring

        igm hollow shaft

        As a unique feature, all media required for welding are passed through the first axis, then through the hollow shaft in the wrist axis, allowing the torch to rotate two turns.
        This significantly improves accessibility with tight workpieces as well as with circular seams. In addition, the collision safety switch-off is also integrated in the torch wrist axis.
        The superb properties of the articulated design and AC servo drives ensure quick acceleration, and gears free from backslash allow for quick and accurate trajectory.
      • Multipurpose Robot

      • Welding, cutting, bevelling and more - Multi-tasking by igm
    • System Components

        • Sensors

            • iCAM igm laser camera

            • Extremely effective, compact laser cameras are used, designed for tracking different welding seam types, for identifying and measuring detected gaps, and for compensating volumes.

              Synchronized laser scan technology

              The camera is based on synchronized laser scan technology, featuring high speed stability, large and programmable workspace, deep visual range, and robustness regarding ambient light and reflections.
              Impassivity against high frequencies and magnetic fields makes it an ideal device for many industrial processes under rough conditions.

              The igm laser camera iCAM is mounted on the wrist axis of the robot. It measures the position and volume of the weld groove online and adjusts the robot movement and the welding parameters accordingly. For the purpose of welding in narrow workpiece ranges, the camera can be automatically deposited and readopted during the welding program.This igm developed laser camera iCAM offers as an outstanding feature the complete integration into the robot control. Thus programming is done with the igm teach pendant K6 without the need for an additional PC. The user benefits from the wide range of languages, European as well as Asian ones, being supported by the robot software. By means of the logging function the whole joint geometry can be displayed, indicating gaps and volumes. A live view of the measuring field is given by grey scale value image. Optionally the camera can be mounted to a rotation device, integrated in the robot controller as sensoraxis.

              Features of the laser camera, type iCAM

              • extreme compact design - best accessibility for arc welding, optionally integration with sensoraxis
              • user interface completely integrated in K6 control software, also in offline mode
              • automatic control of exposure and laser power, adaptive sontrolled ROI (Region of Interest)
              • Ethernet interface (100Mbit) and serial interface (RS422 galvanic separated)
              • 6 predefined + 1 user joint types, 240 user definable profiles
              • languages supported: English, German, Chinese, Swedish, French, Dutsch, Spanish, Italian, Czech, Hungarian, Finish, Russian, Korean
            • The igm laser sensor (iLS) is programmed via teach pendant directly - without an additional PC

            • The igm laser sensor is programmed directly from the robot teach pendant, without need of an additional computer.
              Integrating the user interface into the teach pendant creates a more stream line workflow. All functionality of iLS are supported by the igm offline teaching system.

              The igm Laser sensor (iLS) is useful for applications where edges, gaps and complex structures must be searched for. The sensor may be used for thin and thick metal sheets as extension to or instead of tactile sensing systems. Shifting is computed effectively compensating height and width deviations. Comparing with conventional tactile sensors, the iLS essentially reduces non-productive times by using high search speeds and by simultaneously detecting height and lateral position during a single search path.

              The iLS shall be applied when other sensor systems can not be used due to sheet thickness and / or accessibility.

              The iLS is mounted to the robot's wrist joint either fixed or detachable. The exact position in relation to the welding torch even after several exchange cycles is assured by a rigid bracket.

              There are calculated the displacements, gaps and height of the edges. This additional information can be used for the subsequent program steps. Examples for this application are the filling of seam volume with variable gaps as well as conditional jumps.

              The iLS is programmed directly in the robot control without additional external PC. The integration into the user interface of the teach pendant allows most easy programming.
              Any insertion of parameters is done in the same conclusive way as robot teaching with robot control software K6.

              iLS Features:
              • direct programming
              • no additional PC required
              • digital signal transfer to control
              • full K6 offline support
              • sensor signal displayed on teach pendant
            • Arc seam sensing - precision welding of fillet and V-seams

            • During the welding process arc seam sensing is used to compensate for positional tolerances of the welding seam.

              Perfect control of welding

              By means of a special software and specifically designed hardware, the "actual" seam position of fillets and V-shaped joints is computed by processing data measured while arc weaving, giving a corresponding shifting of the original programmed point/s to the true seam position.

              This arc seam sensing technique can be used with a complete range of welding transfers such as short arc, spray arc and pulsed arc welding - using single or Tandem applications.

              By processing data regarding the welding current variation, the robot control system is able to determine the exact welding joint position in 3D during the oscillating welding process. Originally programmed paths are corrected accordingly. The programmed path is corrected on-line in such a way, that the robot follows the joint in all 3 dimensions and keeps the stick out constant throughout the entire welding seam.

              Function principle of the arc seam tracking sensor

              This online welding seam tracking process is realized by the patented and proven arc controlled seam tracking sensor, type AST.

              A built in welding current measuring system via a shunt resistor is permanently measuring the welding arc. The AST sensor card is evaluating the measurement and recording the values at each oscillating point and the middle point. The measurements of the first few oscillating points are recorded and then kept constant throughout the welding joint.

            • Tactile sensor - igm gas nozzle searching

            • This tactile sensor is used to determine the workpiece position or its components and individual parts by gaging the surface of the workpiece. In each case, the successional part of the program is shifted according to determined deviations.

              igm - robots with sensor shift

              Sensor shifting may be applied for correction of an arbitrary amount of individual points, entire sections of a welding program or entire programs. Combination with arc seam sensing is feasible. The control system supports shifting, rotating, and tilting of a program, depending on position change.

              Function principle of the gas nozzle sensor

              A control voltage is applied on to the gas nozzle and then a various number of searching runs are performed. As soon as the gas nozzle comes into contact with the work piece, it is discharged and the robot stops immediately. This discharge is recorded on-line by the respective sensor board in the control cabinet and subsequently the robot moves to the next searching run.

              After having completed the search runs, the robot controller is shifting the respective program part accordingly.

              Sensor program shifts may also be nested, that means, additional search sequences and blocks to be shifted may be programmed within an other block to be shifted.

              The sensor shifting feature can be used to correct any number of single points, complete sections of the welding program, or complete programs.

          • Control System

              • igm Teach Pendant K6

              • All robot functions may be controlled by the outstanding teach pendant K6 without an additional keyboard. The resistant plastic housing makes for an extremely light weight of 1.3 kg; The lightweight teach pendant includes a 8.4” touch screen, an USB plug on the back is provided for memory sticks. The pushbuttons may be easily used and operated even when wearing protective gloves; the pushbuttons as well as the optional joystick are designed for heavy use.

                igm robot console

                The teach pendant may be used by right and left handed persons and may also be operated in awkward positions.

                Following operating languages are currently available by default and can be changed anytime at runtime:

                English, German, French, Spanish, Italian, Swedish, Dutch, Finnish, Czech, Hungarian, Chinese, Russian, Korean, Turkish, Polish

                As a key element of the RCE control system, the unique teach pendant K6 assembles all the control functions of the RCE control system. No additional keyboard is necessary.

                The industrial design award winning lightweight teach pendant is made out of a high resistant plastic mould and a keyboard panel at topside with an embedded LCD touch screen. The sensible buttons are palpable to enable the operator to touch and feel each button even with working gloves on, compared to a touch screen display.

                The revolutionary and widely favoured shape of the teach pendant allows a right hand and left operation as well as many other holding positions.

                A clear and simple display of each axis button allows the operator a distinctive movement of each axis without pushing the wrong axis button my mistake.

                A courser block offers easy navigation in the RCe software menus and replaces any necessary mouse.

              • The control cabinet for igm robots

              • The RCE control system is based on a standard PC with current processor technology. The complete control system for the six robot axes and up to ten external NC axes is included in a compact control cabinet connected to the robot, the teach pendant, the operating cassette, the external axes, and the power source by cables, pluggable on both sides. The RCE system includes fully digital servos controlled through EtherCAT.

                Concept of RCE control system

                The control system is a fully digital controlled system. This means there are only digital signal processors (DSP) involved in the entire control system and not any analogue electronic component. All the components of the control system, such as control cabinet, welding power source, each axis and the teach pendant are linked by a digital bus system.

                A full digital robot control system brings the following advantages:

                • No influence by any environmental disturbance like inductive fields of welding cables
                • Quickest response time by fastest bus connection > smooth motion of robot
                • Absolute reproducibility of welding result > highest consistency in welding quality
                • Easy diagnosis possibilities of the entire robot control system > less skills and no special instruments for diagnosis are necessary
                • By using modular drive technology and standard PC components a high reliability is guaranteed and the ability to remain constantly at the cutting edge of technology.

                Standard scope of supply of the control system RCE:
                • Control cabinet RCE
                • Teach pendant K6
                • Operating panel BK
                • UPS battery buffer system
                • Robot welding software RCE
            • Periphery

                • Robot periphery

                • The basic device is mounted on the robot periphery in an upright or suspended position. The external axes of the track systems are fully integrated in the control system as NC axes, significantly extending the working area of the robot.

                  A variety of different rotating and linear units are available, either as single axes or combined with up to three positioning units. It is also possible that several robots share a track axis. The positioning range of a longitudinal axis is up to 100m.

                • Workpiece periphery

                • The workpiece periphery holds, positions, and moves workpieces. The external axes are fully integrated in the control systems as NC axes and, in addition, feature manual control functionality. External axes may be included in workpiece manipulation during execution of welding steps. Using the teach pendant, they are programmed together with the robot axes.

                  A variety of different rotary modules is available, as a single axis or combined with up to three axes with a load capacity of up to 25.000 kg.
                • Portal systems

                • igm offers portal gantry systems for welding large-scale components, customized for individual applications. Portal gantry systems range from a track gage of 3 to 25m with vertical tracks of up to 6m positioning range.

                  One or two robots may be mounted on a portal; since the portal axis is controlled by the robot control system, it may also be used for positioning during execution of a welding step.

                  The standard portal design includes a double-sided rack drive with AC servo motors, stable wheel house with integrated edge guide control on massive rails, moving control cabinet, power source, and a control console, if requested.
              • Equipment

                  • igm torch exchange system

                  • Single wire and tandem processes may be used with a robot by exchanging the welding torch. The exchange process includes threading the torch through the hollow shaft and tightening it by a rotary motion.

                    The hose packets always stay connected with the torches during the exchange processes. All welding media may be centrally passed through the hollow shaft. This design continues to support a significant advantage of the igm concept: No passing of hose packets outside of the robot's wrist axis for maintaining full torch movement.

                    Automatic torch exchange system

                    The igm welding robots can be equipped with an automatic torch exchange system, integrated into the hollow shaft of the wrist joint axis.

                    Due to the hollow shaft in the wrist joint, the various torches (with hose packages coupled) can be fed through. Fixing is assured by a rotation movement.

                    This unique arrangement offers the following advantages:

                    • All media are lead through the robots wrist joint
                    • Torch can rotate almost 720°
                    • Flexibility of robot arm remain
                    • Extreme slim design
                    • Combination single wire - TIME TWIN possible
                    • Short changing time - approx. 10 s only
                  • igm welding torch

                  • A broad palette of torches is available for every welding or cutting application with igm robots - ranging from straight torches or curved standard models to the 85° curved type, also available as special types on request.

                    All models feature an extremely stable design and (for MIG/MAG welding) integrated water cooling for torch body and nozzle. Torches are mounted at the robot's wrist flange through quick coupling and may be loaded with up to 900A with the tandem process.

                  • igm Torch Drive

                  • The extremely compact feed mechanism guarantees reliable wire supply including thin and soft additional welding materials.

                    Media feed through hollow shaft

                    Precision The special design with two or four driven rolls allows for integrating the feed in the robot's front axis with single wire and tandem processes. The media feed through the hollow shaft, particularly advantageous for welding applications by allowing almost 720° torch rotation, is also supported for this type.

                    The built-in, sealed cover reliably protects the feeding unit from contamination during the welding process.

                • FMS - Flexible manufacturing system - Robotic production lines

                • For special applications, igm produces customized constructions for your individual needs. The applications are for example gas bottles machines, straight line machines or complete production lines.

                  In these flexible systems more than just the welding technology is required: loading, conveying, stretching, bending, cutting, measuring, manipulating, editing, storing, unloading, controlling.

                  Complex manufacturing tasks require flexible solutions. igm has experiences over many years in engineering and realization of full automatic manufacturing lines for various piece parts sub components. For additional production requirements we provide handling devices, we develop special purpose machines and take care of your whole project from order placing up to final commissioning as a main contractor.

                  Basic concepts of flexible manufacturing lines:
                  • FMS for a single work piece type and a single robot cell
                  • FMS for several work piece types and a single robot cell
                  • FMS for a single work piece type and several robot cells
                  • FMS for several work piece types and several robot cells

                  Components of manufacturing lines
                  • Loading- / unloading stations
                  • Roller conveyors
                  • Conveyor carriage
                  • Buffer stations
                  • Storage places
                  • Line control
                    • Processes

                        • Power Sources for igm robots

                        • Power sources from many well-known manufacturers can be integrated with our robot systems for welding and cutting applications. Products range from digital inverter power sources for MIG/MAG welding, TIG applications, plasma cutting and welding apparatus to high-capacity devices for the tandem process.

                          Should your preferred welding power source not be included above - it's not a problem - our department for welding technology will be pleased to facilitate your individual requirements with regard to connecting the power source interface.

                          Welding and cutting processes

                          igm robots may be used for all non-contact welding and cutting processes. Depending on material and sheet thickness processes such as WIG welding, MIG soldering, plasma soldering or plasma welding are used.

                          Leading welding technology from single to tandem process

                          The main application area is the MIG/MAG welding process: the spectrum ranges from single wire to the tandem process, from steel to aluminum, from sand blasted to primed sheets.

                        • Summary of the welding processes

                        • Welding means the permanent joining together of components by means of heat or pressure, with or without welding additives. igm has specialized in arc welding, one of the oldest electrical welding processes for metallic materials. This arc between a consumable electrode as additive material and the work piece, functions as a heat source when welding.
                           
                          • Arc Welding MIG/MAG
                          • Tungsten Inert Gas Welding TIG Cold & Hot Wire
                          • Plasma - welding or cutting
                          • Friction Stir Welding
                          • Laser-Hybrid Welding
                          • Spotwelding / Tacking
                        • Brushing, Grinding and Handling - Manipulating using Robots

                        • Through the possibilities afforded by a modular configuration of robot cells and the integration of diverse tools in the robot control sequence, significantly better throughput times and constant process qualities can be achieved. As specialist for special machines, igm undertakes the complete designing of the necessary machines.

                          We will be pleased to utilize our 40 years of experience in the sphere of realizing customized complete solutions with the aid of a robot, not only in the welding sector. Innumerable examples of applications in other sectors speak for themselves.
                      • Offline teaching

                      • Welding robot offline teaching - developed by igm

                        Operational availability of the robot installation for production is increased by using an off-line system for generating robot programs. While saving time, programs may be prepared more conveniently in an office environment and simulation test runs (accessibility, computation of cycle time) may be performed. Collisions of the robot with the workpiece or fixtures may be detected at an early stage.

                        Offline teaching - Online working

                        Simple robot programming is available through the self developed PC-based off-line teaching system, using the original software of the robot control system and the teach pendant K6.

                        Offline teaching involves work-piece-oriented programming in 3D mode using a PC and simulation software. The workpiece is first imported into the programming system as 3D-CAD geometry, then the movements of the robot are determined. For path generation and definition of the processing parameters, a number of automatic functions as well as data bases stored in the control system are available.

                        It is a simple system identical to that for programming the robot system on the factory floor, but with a significant advantage: When the teach pendant K6 is employed, an identical software is used for all calculations. This means that conversions of machine parameters or robot programmes of any kind are unnecessary. All programme changes for the system can be processed using the offline system without any conversion losses.

                          • igm bevelling machine iBS

                                  • iBS System Configuration

                                  • Sensor-controlled bevelling system for automated welding seam preparation with plane steel plates. The stable portal construction including application-oriented design of the cutter head supports all types of upper side or bottom side cuts with sensor-controlled edge tracking.

                                    igm-robots: leading by laser technology

                                    A laser camera measures the workpiece position and tracks the edges, ensuring requested base heights with a tolerance of +/- 0.5 mm even with heat distortion.

                                    The system processes the required bevels, which are defined by simply clicking and indicating the geometry parameters in a CAD drawing of the component, with the specially developed software.

                                  • Software for Flame Cutting Operations

                                  • This software is optimized for especially easy setting of work programmes for flame cutting chamfers on flat sheet metal. For this purpose the control system calculates all positions of the axes of the flame cutting system, from the work piece contours determined offline and the numerically specified chamfer parameters (chamfer angle, web height or chamfer width and chamfer depth), taking into account the programmed thickness of the sheet metal as well as the specific torch parameters (kerf width).

                                    Further Advantages for Flame Cutting Operations:
                                    • any number of programmes with up to 24 character alphanumeric programme names
                                    • automatic programme relocation to the various work stations, depending on which work station is selected on the operating PC
                                    • technological parameters such as gas pressures, cutting speed, nozzle separation distance and pre-heating period are contained in a table and must not be specified for setting the programme.
                                    • online correction of gas pressures, cutting speed, cutting line width, nozzle separation distance and pre-heating period
                                    • flame monitoring, so that should the flame be extinguished, the system is immediately stopped
                                    • Leak sensors, in case of a gas leak the installation will be stopped immediatly
                                    • If the cut is interrupted, it is possible to travel backwards and forwards in the previously covered path. The pre-heating period is automatically applied when re-starting
                                    • Automatic cut compensation
                                    • DNC interface for operating programmes created offline
                                    • Pre-selection of the programme to be completed on the operating PC with visual display of the cutting table and the tooling prepared
                                    • Download of programmes from the operating PC
                                    • Automatic completion of programmes selected on the operating PC
                                  • iBS Control Concept

                                  • The controls are a fully digital system. This means that there are only digital signal processors (DSP) and no analogue components included in the whole of the control process. All control components (control cabinet, computer-controlled axes and teach pendant) are connected to each other via a digital bus system.

                                    Advantages:
                                    • No interference from ambient influences such as inductive fields of power cables.
                                    • Fast reaction thanks to bus connections > smooth movements
                                    • Absolute reproduction of cutting results > greatest continuity of quality
                                    • Easy diagnostic of the complete control system > no special instruments required

                                    Through using modular drive technology and a conventional industrial PC, a high availability is guaranteed - always at the cutting edge of technology.

                                    Teach-in Programming:

                                    Using a programming point in place of the cutting nozzle, the prominent points of the work piece contour are traced on the edge of the sheet metal and whilst simultaneously digitally entering the chamfer angle and fillet height or chamfer width and depth, they are saved.

                                    This is done with the teach pendant, the menus of which have been extended accordingly.
                                  • Offline Programming

                                  • An important factor in developing this control software was the wish to significantly simplify the offline programming. Since all calculations of the axes positions are made by the control system, the programmes created offline must only additionally contain the work piece coordinates or those which contain information pertaining to chamfering.

                                    At the very least, the greater part of this component-related data is available at customers and can be utilized for setting the cutting programmes. Only a little information in addition to the data which is anyway required for flame cutting on sheets for 2-D systems, must be specified. All options described can be used in programmes created offline.

                                    If the design of the component has already been made using CAD systems, the programmes for chamfer cutting can be generated from the CAD work piece data (dxf files) using a post processor.

                                    Programmes in an ISO code in conformance with DIN 66025 (numerical control of machines; format, preparatory and miscellaneous functions) are automatically created with the operator-friendly software MSVR.

                                    Since the same data for flame cutting the contours can be used for flame cutting chamfers, the programming is significantly simpler and eliminates many errors.
                                    On the other hand, the tolerances which occur on flame cutting systems cannot be taken into account.
                                  • igm Laser Edge Sensor

                                  • Optimum results can be achieved with the use of this sensor which has had its hard and software optimized for continuous torch tracking.

                                    Here, a water-cooled laser camera is involved which looks at the cutting edge in front of the cutting torch and regulates its position.

                                    At the same time, possible burrs on the edges of the blank cut are hidden by the sensor control software.

                                    The control system determines the correct position of the torch using the position of the sheet metal edge determined by the camera and the known chamfer parameters.

                                    The use of the camera is possible for top chamfers with a width of maximum 140 mm and bottom chamfers with a fillet height of maximum 140 mm.

                                    By means of the laser, the torch is always guided into the correct position to the sheet metal edge, namely before the start of the flame cutting process, to search for the work piece position as well as continuously to track the edge during cutting. By this means a precise adherence to fillet height is possible, irrespective of all cutting tolerances of the sheet metal blank as well as of slow heat distortion.
                                • Applications

                                    • Earthmoving with igm welding robots

                                    • Our installations for the manufacture of excavating machines consist of stand-alone machines or complete production lines with multiple welding cells and systems for automatic loading and unloading. Welding requirements are often demanding due to extreme material thickness, however, our robots are able to cope with position tolerances, seam displacements and welding distortions by means of laser camera systems which allow extremely accurate welding.

                                      End product: Wheel Loader
                                      Components:
                                      • bucket
                                      • lift arm
                                      • front frame
                                      • rear frame
                                      • End product: Excavator

                                      End product: Excavator
                                      Components:
                                      • bucket
                                      • arm
                                      • boom
                                      • upper frame
                                      • center frame, car body
                                    • Railway Industry with igm welding robots

                                    • igm supplied numerous robot systems worldwide for welding various components for rail vehicles, including motors, frames, pivoted bogies, side panels, roofs, front panels for freight cars and wagons, locomotives, high-speed trains, subways and streetcars.

                                      End product: Locomotives
                                      Components:
                                      • main frame
                                      • buffer
                                      • motor cases
                                      • bogie

                                      igm specializes in custom welding robot systems for tasks such as the production of bogies and their components. For the subassemblies, floor tracks with rotary arms are usually used; during assembly, the robots are placed on 2- or 3-axis slide systems. L-shaped manipulators are often used to permit high-quality welding in the flat position.

                                      In the complete fabrication of passenger cars, different processes such as MIG/MAG, plasma, contact points and resistance welding are combined on fabrication lines with corresponding clamping and transport systems.
                                    • Fork lifts with igm welding robots

                                    • Hydraulic cylinders

                                      For the manufacture of hydraulic cylinders, an automatic system consisting of a robot in a closed station with a transport and clamping device is used. Pipes with a diameter between 50 and 100 mm are machined. A library of preprogrammed processes permits a quick change to new workpiece types.

                                      The length of the lift mast can be up to 6 m for large fork lifts. Due to the telescopic design, the masts are of different length and width, but have a similar structure within each family of parts. Thus to modify the robot programs, the igm offline program assembly system iPAT is used, permitting the shifting and copying of program steps or groups of steps on the PC. The geometric data can be read from the CAD system through an interface.

                                      Fork welding

                                      Especially the welding of forks benefits from the consistently high quality of the automation. Despite highly accurate preparation of the parts, the igm robots use a gas nozzle search for position detection and arc seam search to guide the torch along the seam. This is a significant factor in saving costs in the subsequent machining steps by practically

                                    • Cranes with igm welding robots

                                    • More than a dozen different large components for slewing tower cranes, for example slewing platforms or undercarriages for fast-erecting cranes, slewing gear bearings, or slewing ring supports for slewing platforms can be welded by igm welding robots.

                                      With their floor track mounted lifting columns, their rotating cantilever arms, and the axes of the manipulator, the system for slewing gear bearings have a total of over twelve axes and thus the highest possible level of mobility. All axes work with simultaneous movements, so that the robot can even weld very complex parts in the flat position.
                                    • Mining with igm welding robots

                                    • Whether for mining machines for open-pit mining or equipment for underground mining, we offer a custom solution for the manufacture and repair of any machine.

                                      Large excavators for open-pit mining are impressive for their enormous size. Robot systems for the fabrication of undercarriages and slewing platforms are also imposing in dimension. L-shaped manipulators with a load capacity of up to 20 tons and robot portals with 28 integrated axes can even master these welding tasks.

                                      The wear on components for bucket-chain drives (sprocket angles) are automatically measured for the robot using a laser sensor. Build-up welding is then correspondingly used to restore the original dimensions. That saves a lot of time in part refurbishment and ensures the more accurate planning of replacement parts.

                                      But for stationary machines, too, igm robot systems can be used effectively.
                                    • Boiler and vessels with igm welding robots

                                    • Boiler

                                      High-quality boilers are clad on the interior with stainless steel sheet metal to avoid corrosion. That means that both black/black and black/white welding joints are required during fabrication. Both joints are handled in a robot cell using an automatic wire changer system. This system permits the complete welding of the boiler in a clamp without manual intervention.

                                    • igm welding robots for different applications

                                    • igm also offers appropriate solutions for unusual applications. Regardless of whether you want to automate production of aluminum ladders, look for an economic way to weld boilers, manufacture garbage containers, construct bridges or cable cars, are involved in air-conditioning technology or want to teach your students - we can offer the appropriate type of equipment for every application!

                                      Do you want to automate your build-up welding, do you have to change between MIG/MAG and TIG in your fabrication processes, do you have to weld within a narrow temperature window? We can also take these specifications into consideration in the planning of robot cells and selection of system equipment