The igm reputation as a specialist for large-scale projects is based on a steady stream of major contracts from the heavy engineering industry since the 1980s. Indeed, the floor track systems of up to 100m in length are designed to cater for the special requirements of this industry. Components with larger than standard dimensions such as those found in bridge construction and ship building for example, are manufactured using portal welding units capable of taking components of up to 25m in width and 8m in height.
The robotic systems are utilised amongst others for manufacturing excavators, railway wagons and locomotives, for boiler making, the construction of gantry cranes as well as for bridge construction and ship building.
01.
Extreme material thickness capacity
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.
Examples for end products:
02.
Rail vehicles of every kind
When igm robots weld, precision comes into play. Our robot systems weld many parts for rail vehicles all over the world. Engines, frames, bogies, side walls, roofs, front walls for freight or passenger cars, locomotives, high-speed trains, suburban trains, subway and tram cars are products igm robots are working on.
Especially for the evermore frequently used aluminum construction, igm can score with specially equipped robot systems: precise wire guidance by the ‘Torch Drive’ feed motor in the hand axis, the self-developed iCAM laser camera for high-precision guiding of the welding torches along the seam, even with positional tolerances, and if required preheating devices, temperature sensors, pressing and cleaning devices.
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03.
Automated welding on various scales
igm has great experience in the realization of robotic systems for the production of forklifts and plays a key role in customized welding solutions for lift masts, lattice masts, main frames, engine frames and 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. The length of the lift mast can be up to 6m for large forklifts. 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.
Robot systems for the welding of the main frame consist of a 3-axis slide system and an L-shaped manipulator. This permits the workpieces always to be turned into the best position for access and welding. If the hydraulic and fuel tanks are integrated into the frame, seal welding permits them to be taken care of at the same time. The fasteners are welded at the end.
For extreme productivity requirements, automatic fabrication lines are available for main frames. These flexible manufacturing systems (FMS) are designed for the machining of a single workpiece type in multiple identical robot cells. The individual robot welding stations are connected by an automated transport system. The carriage moves on rails and carries a satellite carriage that can move into each station for loading, unloading, preparation and welding. The workpieces are automatically clamped by a special mechanism.
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04.
Reach higher quicker
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.
System examples
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.
Large components - such as slewing platforms for slewing tower cranes and fast-erecting cranes - have a width of up to 2.5m and a length of up to 6m. The manipulator used is one of the largest ever built. Its 3.5m rotating arm pivots workpieces weighing 10 tons. An integrated hoist lifts and lowers the rotating arm by two meters. The faceplate is used to achieve the degrees of freedom needed for welding on all sides.
igm dual robot systems weld the trusses of slewing tower cranes. In the centrally located headstock manipulator, workpieces up to 12m in length are held in a rotating manner, while robots move laterally on floor tracks. Synchronization between the two robot controllers ensures strict compliance with the welding sequence.
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05.
Where size matters
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 be mastered.
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06.
Automatic wire changing system
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 changing system which permits the complete welding of the boiler in a single clamp without manual intervention.
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07.
Numerous possibilities for efficiency
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!
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We can also take these specifications into consideration in the planning of robot cells and selection of system equipment.
Postal Address:
PO Box 457
Kent Town SA 5071
Australia
See the potential in action:
To support our existing and future customers, we have installed a full six-axis welding robot with a laser camera, twin welding, scanning, and offline software at our offices for testing, trials, simulations, training, general support, and customer assistance.
