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Precise, quick and reliable: The use of laser beams in the welding and cutting technology offers many advantages. CLOOS presents the QIROX Laser Cell, a new product line of compact cells for automated laser cutting and welding.
The demands on productivity, repeatability and quality are continuously increasing in industrial production. This has to be met by the welding and cutting technology, too. Modern welding technologies allow increasing the quality, productivity and efficiency of the complete production process. The importance of laser welding and cutting in particular will grow in future. The main reasons for this are the high efficiency and accuracy of the laser beam. Laser welding and cutting often allows a much higher process speed with at the same time a better quality than with conventional processes. The exact work with a precise heat input minimises the heat affection and thus the thermal distortion. This reduces any time-consuming rework to a minimum.
With the QIROX Laser Cell CLOOS developed an extensive range of laser cells for maximum efficiency and quality. Each laser cell system is a tailor-made unit with components which match each other perfectly. They do not require much space and can be easily integrated into any production. The turnkey systems consist of a laser welding head, safety equipment, operating terminal, positioner, QIROX robot, flat screen with HD camera for visualisation and a pre-assembled media room.
The laser cells are equipped with a high-tech diode laser offering a maximum electrical efficiency. Other features of this laser type are the high availability, low maintenance expenditure, easy operation and an excellent process stability.
The 2-station systems are available with different types of positioners for different workpieces and can be loaded from outside. At one end employees can remove the welded workpieces, check the quality of the welding and reload the system while the welding process takes place at the other end. This results in an enormous saving on time for the whole process.
CLOOS develops, manufactures and delivers innovative solutions to more than 40 countries worldwide. With our QINEO®, the new generation of welding machines for manual and automated applications, and QIROX®, the system for automated welding and cutting, our product range covers the entire spectrum of arc welding technology. Our product portfolio includes intelligent software, sensor and safety technology solutions – all of which are customised to meet your specific needs and requirements! Leadership and competence equals process automation and welding at its best. Whatever your needs are, we “Weld your way.”
Fendt is the high-tech brand within the AGCO corporation which is one of the biggest manufacturers and suppliers of tractors and agricultural machinery in the world. The company depends on the technologies of Carl CLOOS Schweisstechnik GmbH for welding the safety cabs for its tractors. In the two-station system, two robots weld components of the cab floor assembly. Here the Vari Weld process is used which creates an extremely stable and low spatter pulsed arc. The robots are equipped with a tool changing system and tack the threaded bolts on the floor assembly after welding. The robots are mounted on a positioner with vertical stroke.so that they can flexibly move to the optimum welding position. The two-station positioner with horizontal station change allows loading and unloading of the workpieces at the same time when the robots weld. Both stations are equipped with a turning and swivelling axis. Thus positions which are difficult to access can be reached and an optimum weld quality is achieved.
Modern harvesting machines are very complex units which allow to carry out many steps of the harvesting process in a confined space. To ensure highest reliability the individual components must be perfectly constructed regarding functionality, robustness and weight. A welding robot mounted overhead on a C-frame welds different medium-sized thin plate components. The robot system is equipped with a double-station positioner which changes the station with a horizontal rotary axis. Each of the two stations is equipped with a turn/tilt positioner with counter bearing. Due to the arrangement of the turn/tilt axes even complex workpieces can be perfectly positioned for welding. Thus positions which are difficult to access can be reached and an optimum weld quality is achieved. The stations have quick clamping systems so that the working stations can be retrofitted to another workpiece within a few minutes. Thus retrofit times are reduced to a minimum and the efficiency of the robot system is guaranteed also in the case of frequent retrofits.
CLOOS robots used for welding aluminium tanks for HGVs. The two-station robot machine – fitted with the most modern welding technology – guarantees optimum welding results and maximum efficiency. The QIROX QRC 350 robot welder is mounted overhead on a C-shaped frame. This position allows the robot better access to the workpiece. The C-frame is mounted on a floormounted linear track so that the robot can be moved horizontally and flexibly between the two stations. The CST Flex D laser online sensor carries out corrections immediately thus ensuring optimum welding results.
In the Saxon AMS Apparate-Maschinen-Systeme Technology GmbH production the time-consuming manual work of cutting the stainless steel material is done by a robot. Instead of the previous two days manual work, the robot only needs less than four hours. The robot is equipped with a tactile sensor for an exact workpiece measurement. Thus manual marking-out works are not required. And only a minimum of rework is necessary. The two-station system ensures highest system efficiency because the operator works parallel to the robot. Due to the RoboPlan software the workpieces can be programmed offline on a PC during cutting. This considerably reduces the set-up and downtimes. In addition, there is a high level of conformity from the drawing to the product. In this way AMS can produce reproducible components which will make the subsequent exchange of containers simply possible.
Borsig Process Heat Exchanger GmbH manufactures cooling units for gases with high temperatures and pressures in the chemical and petrochemical industry. To weld the thick units, the Berlin company invested in a CLOOS robot system. The robot of the new system welds sleeve nozzles at the heat exchanger casing with diameters from 250 to 500 mm using the MSG nar row gap process. This process offers a particular economic efficiency for welding thick-walled components. Due to the use of the narrow gap technology new system Borsig could considerably reduce the production times costs and - at the same time - increase the quality.
Since last year, the Caldera Heating Group (Bursa, Turkey) has been operating two robot systems from CLOOS. The automated machines weld many different varieties of boilers. Both machines each have two stations and are fitted with a six-axis QRH 360 robot. By introducing automated welding, Caldera was able to increase the productivity and the quality of manufacturing considerably.
Faun as the most successful manufacturer of waste disposal vehicles in Europe offers customised solutions for the most different waste types. The company uses the Speed Weld Process to weld the interior housing of the Variopress container. The main advantage of this process is a very directionally stable and powerful arc. Thus relatively high welding speeds can be reached with the Speed Weld process. Furthermore, a deeper penetration at a high welding speed is achieved. The transversal track with a length of 5 m moves the robot into the container interior for welding the guiding rails.
In the two-station robot system a QRC350 welds different steel supports for systematised building construction. These supports are used for offices, car parking and production halls as well as for municipal buildings such as hospitals, schools and sports halls. The MAG pulsed arc ensures optimum weld seam quality at high weld speed. The welding robot is mounted on an approx. 20 m floor-mounted linear track and has a rotating positioner with counter bearing which is used to always position the supports perfectly for welding.
On an enclosed surface of 5600 x 4400 mm a double station workpiece positioner for a horizontal rotation is placed in the middle. Whilst the root welds in one station, the operator removes the readily welded workpiece from station 2 and inserts a new one. Both stations have a swivelling and turning axis to perfectly place the pump components external housing, impellers and suction connections for the QIROX robot 350E.
As one of the biggest manufacturers of forklift trucks and warehouse handling equipment Linde Material Handling GmbH at its production site Aschaffenburg trusts in manual and automated welding technologies by CLOOS. The flexible robot welding system for mast production was individually adapted to the special conditions at site. As the production hall has low ceilings, the system is positioned relatively widely. The two welding robots are in the middle of the system whilst a track flexibly moves the positioners between the two stations. Due to the large number of variants, Linde Material Handling uses the RoboPlan offline programming software by CLOOS for automated welding. While the robot system is in production, a new program can be simultaneously produced in RoboPlan. The welding, search and travel paths and tools can be determined using 3D models, and the welding parameters and other functions required for running the program can then be defined.
The Manitowoc Group is one of the world's leading crane manufacturers. The US Group produces its GROVE brand auto-cranes at the Wilhelmshaven site. To increase competitiveness, the company is currently investing in state-of-the-art production technology and optimised material flow in the traditional manufacturing shops. Its heart is a 60 m-long CLOOS laser welding/cutting system around which the production of the telescopic booms flows.
As a competent system supplier for chassis and frame construction, laser cutting, sheet machining and stainless steel processing, MBH Maschinenbau & Blechtechnik GmbH relies on the latest production technologies, quality and productivity from CLOOS. A highlight is the new robot syste m which allows to weld complex components with different sizes and variants. The system controls two independent, programmable welding robots, which can weld simultaneously on a single component in single station mode, but in two station mode can also process different, smaller component s completely independently. The turn/tilt positioner always positions th e complex workpiece perfectly for welding. Thus positions which are difficult to access can be reached and an optimum weld quality is achieved. The torch changing system facilitates the use of single wire and tandem processes with a single robot. The entire welding process is designed in such a way that welding times and ancillary activities are of the same duration. This is how MBH achieves an optimum degree of utilisation of the system and efficient use of personnel which makes production quick and attractively priced.
F.X. Meiller GmbH & Co. KG is specialised to manufacture tipper bodies and trailers. For decades, the company has trusted in the technology of the welding specialists from Haiger. The fully automated system at the Czech site of Slaný consists of three working stations. Due to the 33 m long gantry the two robots can reach all stations. This ensures the maximum flexibility and efficiency of the system.
For many years, Siemens has belonged to the group of leading manufacturers in the world with innovative gas turbines for power stations. In order to be able to manage the greatly increasing demand and at the same tim e improve the working environment for employees, Siemens is using narrow gap welding by means of robots for handling huge turbine housings weighing up to 80 tons. Up to 300 mm thick plates can be welded without an extensive weld preparation. Compared to the previous manual welding the production time reduces by more than 80 %. There is an enormous potential saving with regard to the filler material, shielding gas and power consumption. And the relatively low heat input reduces the material distortion during welding. The use of the narrow gap technology considerably increases the efficiency of the robot system and leads to an improved welding result.