On display will be a robotic Non-Destructive Inspection system, the NSpect 210.  Parts will be robotically picked from load stations and manipulated in front of an immersed 64-element ultrasonic array working in Pulse Echo.  The system will collect full waveforms and display live A, B and C-scan images.

Based out of San Juan De Rio, Genesis-ICESA Systems pulls strengths from Genesis Systems Group and ICESA Modicon to become the most capable robotic systems integrator in Mexico.   The expertise of the two companies will broaden the product and processes offered to all of our North American customers.

Tina Katzenburger has been promoted to the position of Global Support Specialist.  Bringing proven Customer Service skills and knowledge of Genesis business practices to the team, Katzenburger will report to Doug Boyd and join in developing the tools and processes required to support current and developing international affiliations.

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Are you interested in signing up for our PM reminder program?  Our service staff can set a reminder to call or email you when your system PM is due.  At this time, a quote can be generated for parts and/or service support as needed.  Contact Us if you are interested.

North America’s largest metal forming, fabricating, welding
and finishing event heads to McCormick Place, Chicago, IL, November 14-17, 2011!  This annual event anticipates 30,000 visitors and over 1,200 exhibiting companies covering more than 410,000 net square feet of floor space.  Stop by Booth 5933 to see what Genesis Systems Group has to offer.  Register today!

• Genesis’ NEW Center Mount Servo Turntable
• Press Tending & Material Handling Demonstration
• Robotic Weld Inspection & Repair
• Genesis Motorcycle Frame Fixture
• Advanced Engineering Simulations using Delmia V5
• Genesis Intelligence Center
• Variation Analysis Weld Fixture Demonstration
• Social Media Showcase
• iPad Giveaway

Mike Jacobsen, Process Engineering Manager, of Genesis Systems Group in Davenport, Iowa, comments, “During or after economic downturns, manufacturers are often reluctant to add employees as production demands return. This may actually be an opportune time to increase employee productivity by investing in automation.”

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Project Challenges

• Multiple part sizes and heat requirements
• Extreme heat of reaching 2000-degrees
• Traditional fusing process is achieved by sight and is very operator dependant
• Robust controls package to closely monitor the process while allowing for easy operator interface

Genesis Solution

• The Genesis Team designed a lathe system to turn the part using a Cone Drive gearbox and VFD. The tailstock needed to adjust for two different length parts. Tool changers and torch lighters needed to be designed into the system to enable the robot to automatically change between the double rosebud torch and the flame spray gun. Torch lighters are automatic and the flames are monitored. Every process is tightly controlled for quality and operator safety.
• The tailstock and headstock were designed using a special spacer to isolate the heat from the tailstock bearings and the headstock gearbox. Special linear bearing seals were included in the design. A 1500-degree robot suite was employed to protect the robot. Gearboxes and cylinders were ordered with high temperature seals. Guards and covers were added to deflect the heat from reaching the robot.  A special side draft heat/smoke extraction wall was included.
• Since the fusing process is normally completed by sight, the Genesis Team needed to develop a process that is consistent and repeatable. To aid in the process, Genesis automated the temperature sensing and the measurement of the thickness of the sprayed on material. The number of robot passes is defined and adjustable based upon multiple conditions, such as humidity, metallurgy, ambient temperature, and mass of material. Robust and flexible!