New System Generation for Studwelding

Today: DCE, ETF und LM

 100 to 500 studs per car

 10 - 80 systems per line
 12.000 systems installed

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Project Targets

 Market study in July 2007

 Simplify usage
 Grow reliability
 Reduce maintenance effort
 Extensions during development phase
 Reduced cycle time
 Energy efficiency
 Flexible communication structures
- I/Os - Feldbus
- Data management – Network
- HMI Strategies
 Tightened security guidelines as a consequence of EC Machinery Directive
(Performance Level D)

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New: TE 1500, TF 21, TH 510, HMI

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System Layout – Weld Head

TF 21

TH510

TE 1500

GAS

Compressed air

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System Layout – Weld Gun

TF 21 PLM 200

Legacy
TE 1500 Box

GAS

Compressed air

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New Hardware and Software Architecture:
TE 1500, TF 21, TH 510
 Same µC in TE for SMPS (weld current) and LM (stud motion)
Identical weld process as usual
… allows for future process extention for
- New steel alloys
- New coatings
- AC stud welding for Aluminium
- Ring flange studs
 Fully monitored and event controlled feeding process
 Reduces sources of errors
 reduces cycle time
 reduces energy consumption (air),
 simplifies trouble shooting
 allows predictive maintenance

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New Hardware and Software Architecture:
TE 1500, TF 21, TH 510
 Energy distribution architecture (valves, transformers, etc.)
 reduces cycle time
 reduces energy consumption (air and electricity)
 in line with AIDA PEC requirements (sleep by wire, etc.)
 able to fulfill performance level D
 CPM board of TE 1500 host state of the Art database an uC
 Networking and data management for all individual customer
requirements
 Customized HMI requirements
 logbook functions
 statistical analysis
 parameter trend control
…. For all individual customer requirements around data management

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Added Value: Cycle Time Reduction
example: SWB 236 T5.14, 6 bar, 8m cable package and feed tube

FK
welding: 1,7 s. Stud feeding: 1,5 s.
DCE 1500 (constant) (constant)

Robot motion
Cycle time Cycle time
reduction reduction
23,5% 46,5%

Welding: 1,3 s. S. feed.: 0,8 s.

TE 1500 (constant) (constant)

Robot motion

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 T5 x 14, 10/car, DCE 1500 vs. TE 1500
– cable pack 10m, 2 cables
pls select Comparison Results DCE 1500 TE 1500
Stud SWB 236 Time LM310 TH510 Savings [ms] Savings [%]
Cable package length 10 Feeding time [ms] 1544 845 699 -45,26
Air pressure 6 Welding time [ms] 1300 950 350 -26,92
TR/LMR angle degree° 135 Welding + Feeding time [ms] 2844 1795 1049 -36,88
Compressed air Reduction [L] Reduction [%]
Enter your
parameters
Air consumption [L] 8,87 3,80 5,07 -57,14
Studs per Car 10 Savings [€] Savings [%]
Cars per Day 800 Air Costs in € per year 234,28 100,42 133,86 -57,14
compl. compl.
Workdays per year 220 Electrical energy Reduction [kWh] Reduction [%]
System DCE series System Tseries
System Lifetime in years 7 Standby [kWh] 876,00 597,60 278,40 -31,78
Costs [Air] cent/m 3 1,50 Welding [kWh] 645,333 645,333 0,00 0,00
Weld current A 1200 Power dissipation [kWh] 240,843 198,181 42,66 -17,71
Weld time ms 50 Total Energy consumption [kWh] 1762,177 1441,11 321,06 -18,22
Degree of efficiency % 80 Primary Energy demand [kWh] 1983,721 1651,99 331,73 -16,72
Arc Voltage V 22 Savings [€] Savings [%]
PEC Level 3 (DCE 1500) W 100 Energy Costs in € per year 198,37 165,20 33,17 -16,72
PEC Level 2 W 40 Savings [€] Savings [%]
PEC Level 1 W 20 Lifetime Costs [€] 3028,56 1859,36 1169,20 -38,61
Costs [Electricity] cent/kWh 10 Ecological balance / lifetime [to. CO2] 21,50 13,20 8,30 -38,61
CO2/Elec. Energy kg/kWh 0,71

Cable configuration
amount of cables 1 or 2 2
diameter 50
cable 1
length 6
diameter 35
cable 2
length 2,5
diameter 95
ground cable
length 8

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 T5 x 14, 10/car, DCE 1500 vs. TE 1500
– cable pack 6m, 1 cable
pls select Comparison Results DCE 1500 TE 1500
Stud SWB 236 Time LM310 TH510 Savings [ms] Savings [%]
Cable package length 6 Feeding time [ms] 1376 631 745 -54,14
Air pressure 6 Welding time [ms] 1300 950 350 -26,92
TR/LMR angle degree° 135 Welding + Feeding time [ms] 2676 1581 1095 -40,92
Compressed air Reduction [L] Reduction [%]
Enter your
parameters
Air consumption [L] 7,92 2,20 5,72 -72,25
Studs per Car 10 Savings [€] Savings [%]
Cars per Day 800 Air Costs in € per year 209,17 58,05 151,12 -72,25
compl. compl.
Workdays per year 220 Electrical energy Reduction [kWh] Reduction [%]
System DCE series System Tseries
System Lifetime in years 7 Standby [kWh] 876,00 597,60 278,40 -31,78
Costs [Air] cent/m 3
1,50 Welding [kWh] 645,333 645,333 0,00 0,00
Weld current A 1200 Power dissipation [kWh] 188,461 145,798 42,66 -22,64
Weld time ms 50 Total Energy consumption [kWh] 1709,794 1388,73 321,06 -18,78
Degree of efficiency % 80 Primary Energy demand [kWh] 1918,243 1586,51 331,73 -17,29
Arc Voltage V 22 Savings [€] Savings [%]
PEC Level 3 (DCE 1500) W 100 Energy Costs in € per year 191,82 158,65 33,17 -17,29
PEC Level 2 W 40 Savings [€] Savings [%]
PEC Level 1 W 20 Lifetime Costs [€] 2806,96 1516,92 1290,04 -45,96
Costs [Electricity] cent/kWh 10 Ecological balance / lifetime [to. CO2] 19,93 10,77 9,16 -45,96
CO2/Elec. Energy kg/kWh 0,71

Cable configuration
amount of cables 1 or 2 1
diameter 50
cable 1
length 6
diameter 35
cable 2
length 2,5
diameter 95
ground cable
length 8

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 M6 Ground Stud, 10/car, DCE 1500 vs. TE 1500
- cable pack 10m, 2 cables
pls select Comparison Results DCE 1500 TE 1500
Stud SWB 533 Time LM310 TH510 Savings [ms] Savings [%]
Cable package length 10 Feeding time [ms] 2204 1471 733 -33,24
Air pressure 6 Welding time [ms] 1300 950 350 -26,92
TR/LMR angle degree° 135 Welding + Feeding time [ms] 3504 2421 1083 -30,90
Compressed air Reduction [L] Reduction [%]
Enter your
parameters
Air consumption [L] 13,82 6,87 6,95 -50,29
Studs per Car 10 Savings [€] Savings [%]
Cars per Day 800 Air Costs in € per year 364,96 181,41 183,55 -50,29
compl. compl.
Workdays per year 220 Electrical energy Reduction [kWh] Reduction [%]
System DCE series System Tseries
System Lifetime in years 7 Standby [kWh] 876,00 597,60 278,40 -31,78
Costs [Air] cent/m 3
1,50 Welding [kWh] 645,333 645,333 0,00 0,00
Weld current A 1200 Power dissipation [kWh] 240,843 198,181 42,66 -17,71
Weld time ms 50 Total Energy consumption [kWh] 1762,177 1441,11 321,06 -18,22
Degree of efficiency % 80 Primary Energy demand [kWh] 1983,721 1651,99 331,73 -16,72
Arc Voltage V 22 Savings [€] Savings [%]
PEC Level 3 (DCE 1500) W 100 Energy Costs in € per year 198,37 165,20 33,17 -16,72
PEC Level 2 W 40 Savings [€] Savings [%]
PEC Level 1 W 20 Lifetime Costs [€] 3943,32 2426,24 1517,09 -38,47
Costs [Electricity] cent/kWh 10 Ecological balance / lifetime [to. CO2] 28,00 17,23 10,77 -38,47
CO2/Elec. Energy kg/kWh 0,71

Cable configuration
amount of cables 1 or 2 2
diameter 50
cable 1
length 6
diameter 35
cable 2
length 2,5
diameter 95
ground cable
length 8

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 M6 Ground Stud, 10/car, DCE 1500 vs. TE 1500
- cable pack 6m, 1 cable
pls select Comparison Results DCE 1500 TE 1500
Stud SWB 533 Time LM310 TH510 Savings [ms] Savings [%]
Cable package length 6 Feeding time [ms] 1976 1040 936 -47,37
Air pressure 6 Welding time [ms] 1300 950 350 -26,92
TR/LMR angle degree° 135 Welding + Feeding time [ms] 3276 1990 1286 -39,26
Compressed air Reduction [L] Reduction [%]
Enter your
parameters
Air consumption [L] 12,42 5,27 7,16 -57,61
Studs per Car 10 Savings [€] Savings [%]
Cars per Day 800 Air Costs in € per year 327,97 139,03 188,94 -57,61
compl. compl.
Workdays per year 220 Electrical energy Reduction [kWh] Reduction [%]
System DCE series System Tseries
System Lifetime in years 7 Standby [kWh] 876,00 597,60 278,40 -31,78
Costs [Air] cent/m 3
1,50 Welding [kWh] 645,333 645,333 0,00 0,00
Weld current A 1200 Power dissipation [kWh] 188,461 145,798 42,66 -22,64
Weld time ms 50 Total Energy consumption [kWh] 1709,794 1388,73 321,06 -18,78
Degree of efficiency % 80 Primary Energy demand [kWh] 1918,243 1586,51 331,73 -17,29
Arc Voltage V 22 Savings [€] Savings [%]
PEC Level 3 (DCE 1500) W 100 Energy Costs in € per year 191,82 158,65 33,17 -17,29
PEC Level 2 W 40 Savings [€] Savings [%]
PEC Level 1 W 20 Lifetime Costs [€] 3638,56 2083,80 1554,76 -42,73
Costs [Electricity] cent/kWh 10 Ecological balance / lifetime [to. CO2] 25,83 14,79 11,04 -42,73
CO2/Elec. Energy kg/kWh 0,71

Cable configuration
amount of cables 1 or 2 1
diameter 50
cable 1
length 6
diameter 35
cable 2
length 2,5
diameter 95
ground cable
length 8

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Economic Value: Weld Head TH 510

 Considerably longer uptime

 Integration strain relief for cable LM 310
package at adapter plate
 Savings with maintenance
 Lower number of spares and
consumables
 Higher availability
 Confusion-proof connetions
 Energy saving
 Energetical optimised feeding process
with Stud Arrival Sensor
 Shorter cycle time
 Optimised LM-drive
 Integration pneumatics (valve cluster in
TH 510
weld head)
 Performance level (D) fulfilled

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TH 510 – Standard Receiver System

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TH 510 – Receiver System with improved Access

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Comparison LM 310 – TH 510

TH 510

LM 310

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Comparison LM 310 – TH 510

TH 510

LM 310

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TE – Single Head Robotic Application with Dress Pack

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TE – Dual Head Robotic Application with Dress Pack

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New Hardware & Software Architecture: TE 1500,
TF 21, TH 510
 Existing handgun with RFID program selection through the jig
 Weld program / outlet number per weld position
 Worker independent
 Several counter options
 Fully traceable weld parameter monitoring

Transponder
PLM 200 / RFID

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New Hardware & Software Architecture: TE 1500,
TF 21, TH 510
 All hardware with pcb ID, counters, memory and serial
numbers on the board
 Traceability
 supports maintenance structures
 Capable to monitor software license via hardware ID
 Customer has the freedom only to buy what is needed
 Plug & Play
 System specific single licencing

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TR 610 in Detail
 Standard welding process like TH 510
 Slide movement
 Probe
 Protective gas
 Modular Design
 Gripper solution with probe
 Single pickup station
 Douple pickup station
 Magazin (concept)
 …
 Aluminium Casting Design
 Rigid cast design
 Less parts
 Less screws

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One Weldhead – 4 Stud Dimensions

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Position Alignment Stop Pin

Stop pin position is defined

with stud pick-up.

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TR 610 in Detail

Feed tubes

Cover
(cable track)

Central Alu-casting unit

Rotation unit

Media connection

Tool

Pick-up Cover (pick-up)

adapter plate

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TR 610 in Detail

Feed tubes and cable

package centralized

Stud Arrival sensors

Probe

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 TR 610 in Detail

Cable track

Programmable
gas valve

Second
measurement
Motor control system
Direct driven
PCB gear motor
(Orientation sensor)

Slow motion-
controller

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TR 610 in Detail

Cable package
fixation point

Tool changer

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TR 610 in Detail

Flexible mechanical stop pin Valves

[Slide, Gripper]

LM actuator
Stud length monitoring with integrated
measurement system

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