Heavy Industrial robotic integration solutions

Premier Heavy Industrial Robotic Integration Solutions

Reduced Cycle Times and Increased Profitability

Helping heavy industrial manufacturers unlock greater levels of profitability and efficiencies, Genesis robotic integration solutions solve production challenges that others simply cannot. Automation for thick plate heavy welding requires careful consideration. With systems designed to ensure the highest quality and repetitive accuracy, Genesis offers custom and turnkey solutions to increase travel speeds, reduce cycle times, and help you meet your ROI objectives.

For decades, Genesis has been developing innovative robotic welding and integrated systems to help heavy industrial manufacturers meet their challenging application needs.

Genesis offers the following robotic integration solutions for general industry applications:

  • Robotic Welding to include:
    • Cold metal transfer
    • Low spatter GMAW
    • High deposition tandem wire
    • High deposition cored wire
    • GTAW
    • Laser welding
    • Resistance spot welding
  • Robotic Material Handling and Machine Tending
  • Dispensing
  • Material Removal to include:
    • Plasma cutting
    • Laser cutting
  • Robotic Tooling
  • Virtual Design Solutions
  • Metrology
View Video Transcript
Manual welding of a 45,000 pound part was proving inefficient, inaccurate and labor-intensive for Hitachi, a manufacturer of large industrial mining equipment. They contacted Genesis, a global leader in robotic automation systems, to tackle this monumental project.

Genesis implemented a custom modular system for robotic welding of very large parts for rock quarry trucks. The system is capable of welding across the entire part. The custom welding module includes headstock and tailstock positioners with elevation and rotation control on an independent Z-Axis. A U-joint design on both headstock and tailstock allows the part to be tilted in either direction for correct weld positioning. Since this feature varied the distance between headstock and tailstock, the tailstock is mounted on a linear track, allowing it to move back and forth as the part is tilted. Two robots are also mounted on linear tracks so they are able to reach and weld the entire part. Most welds in this process are multi-pass welds, often requiring 20 passes or more, due to the large size of the weld joints.

One of the requirements was all welds had to be done in position. This took several professional welders over 70 hours to complete just one part, which greatly affected Hitachi’s profitability and overall time to market. Robotic welding has significantly reduced their welding time, labor costs, downtime and their time to market.

The system features time-saving OLP, offline programming, allowing the robots to be programmed without stopping production. For convenience, the programming interface is right next to the robots, further decreasing downtime and required man hours.

By the time the robotic welding system was assembled, it was ready to start welding – easing the impact of the initial investment and reducing downtime during the implementation process.

Automating welding processes for a 45,000 pound part is no small challenge. Informed by decades of experience and industry-leading expertise, Genesis was able to integrate a robotic welding system that not only performs all of the required welding processes, but also meets Hitachi’s production goals to reduce costs and improve time to market.

For your challenging welding applications, contact Genesis – global leaders in robotic integration.

View Video Transcript
As a leader in robotic integration for welding automation systems, Genesis Systems Group has solved some of the toughest jobs in the industry. This is why a manufacturer of construction and mining equipment chose Genesis to automate their heavy welding processes for excavator buckets. Genesis quickly implemented a custom modular drop axis workcell with a track-mounted robot.

This multi-pass robotic welding system uses touch sensing for weld location and coordinated motion for weld positioning. A two-axis positioner handles the buckets, which can weigh up to 3,000 pounds, enabling complex part manipulation to give the welding robot access to the entire part.

The welding process before Genesis implemented this robotic system took over 6 hours. After the automation system was introduced, welding time dropped significantly, boosting throughput and decreasing their overall time to market.

Not only has the robotic welding system increased the speed of welding, but it has improved the consistency of welding too. Previously, it took 2 hours for welding repairs per bucket, due to inconsistent manual welding.

With robotic welding in place, that time has dropped by 78% per bucket – once again, increasing the manufacturer’s throughput and decreasing time to market.

The heavy-duty two-axis positioner is an important component of this robotic workcell. Handling materials in excess of 3,000 pounds is no easy task, especially for humans. Before the manufacturer contacted Genesis, the buckets were rotated by a system of cranes, chains and a minimum of two laborers. This work was dangerous and slow. Now, as you can see, the two-axis positioner quickly rotates the bucket to exactly where it needs to be, giving the welding robot full access.

For heavy industrial welding, quality, consistency and throughput are all crucial aspects of production.

Boost productivity, throughput and quality by choosing Genesis as your robotic systems integrator.