2016 Miller PerformArc PA550HW Robotic Welding Cell
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**900 Hours Of Program Run Time
Head / tail distance of 60″
Swing Diameter of 40″
550lb payload per side
Servo Indexing Table (Load / Unload)
Common base permits easy relocation
Compact design minimizes floor space
Single Source: ONE CALL: Miller Welding Automation
1.0 Standard Equipment: Fully Assembled and Wired
1.1 Cell Construction
Ø Fully fabricated steel tubular frame with sheet metal wall structure
Ø Framework is unitized; the main robot/positioner/controls section can be picked up from the front or back sides for placement and relocation
Ø All cables are run in discrete paths or under deck plates or above entrance/exit points to prevent premature wear from welding spatter or contact with personnel
Ø All lower cableways are covered with deckling to eliminate tripping hazards and protect the cables from the welding environment
Ø To prevent tripping, the framework is cut out near the maintenance access doors
Ø Two sliding maintenance access doors are included for easy robot maintenance and programming access
Ø Robot riser with robot pre-assembled, dressed and mounted
Ø Robot controller, welder and heavy power connections including transformers (if needed) are pre-wired and pre-assembled to run to a provided single electrical disconnect box at the rear of the workcell
Ø System paint color of standard black
Ø Fork lift access for easy transport
1.2 Panasonic TM-1600WG TAWERS Robot
Ø 4kg Payload
Ø 62.9 inch reach to Point P
Ø Panasonic G3 Robot Controller
Ø Panasonic G3 Teach Pendant (Windows CE 7″ Color GUI)
Ø Automatic Program Backup – Standard
Ø SD/USB ports – Standard
Ø Collision Detection – Standard
Ø Brake releases on arm – Standard
Ø Second and Third Axis over travel switches, limiters and electrical circuits – Standard
Ø Servo Power On Lamps – Standard
1.3 Cell Controls
Ø Heavy electrical power pre-wired and assembled, including common electrical disconnect
Ø Light curtains in L-shape configuration at the front of the work cell
Ø External axis brake release circuit and enabling box
Ø Standard Panasonic cell controls
Ø Start strip is mounted to the vertical tube to minimize opportunity to be damaged during production
1.4 TAWERS 350A 60% Duty Pulse, 80% CV
Ø TAWERS 350 Amp welding systems come standard with Embedded Arc Control (EAC) technology which eliminates the need for three separate control systems and fuses control of the robot, welder and servo wire feeder into a single physical unit.
Ø This new controls breakthrough is contained entirely internal to the robot controller and is monitored by the TAWERS 64-bit main CPU. EAC technology controls not only the robot motion path and sequence commands, but simultaneously synchronizes the welding power supply waveform control and servo wire feeder response accordingly, to adjust and correct for dynamic changes in the welding process.
Ø TAWERS with EAC technology goes far beyond conventional digital communication systems, delivering the first and only generation of fully software-controlled robotic welding solutions.
Ø SP-MAG is a new welding process developed out of industry needs for a more versatile CV welding process. Where conventional and even high-end CV processes have tried to produce low-spatter, high-speed welds, they have missed the mark ultimately demanding lower amperage levels or slower welding speeds to achieve their goals. TAWERS has successfully met these challenges by bringing together the major benefits of Pulse and CV into one process SP-MAG
Ø Ultra-low spatter levels
Ø Low heat input
Ø Low susceptibility to arc blow
Ø Wide process windows across entire amperage range
Ø Excellent thin material and gap handling capability
Ø Spatter is the enemy of every company, big or small. The TAWERS solution takes aim at not only the arc physics that generate spatter, but also other factors that
directly impacts spatter generation. SP-MAG combined with advances in welding arc starting and ending have led to an extreme decrease in the amount of spatter generated during the entire welding process. Extensive testing has shown that a switch from conventional CV to SP-MAG could result in a savings of 100 to 150 lbs less wire purchased per arc.
Ø Reduced or eliminated secondary cleanup operations saving manpower, floor space and limiting total work in process
Ø Using a 100 kHz primary side high frequency inverter, TAWERS offers an extremely fast response, providing exceptionally precise, almost real time, and control of the welding arc.
Ø 10-5 sec (10 micro second) control and correction cycle
Ø 5X faster response than conventional feedback control circuits
Ø Electronic reactor control makes special process inductance taps a thing of the past. Optimum current control during all phases of welding is now possible.
1.5 Step-Down Transformer
Ø The system comes pre-wired to a single disconnect box, with input power of 480 volts, 3 phase, 60 amps suggested service (single robot systems). Other input voltages can be accommodated at an additional cost.
1.6 Operator Control Center
Ø Robot handles all safety supervision through concurrent I/O
Ø PLC used to simplify wiring
Ø Operator Macros for Tip Change and Tip Check
Ø Full Safety Monitoring includes Light Curtains for Operator
1.7 Safety Equipment
Ø Perimeter Guarding – Solid and Wire Mesh Fence Panels
Ø Yellow Arc Curtain Included on Wire Mesh Panels
Ø Dual Safety Sliding Gates – Interlocked
Ø Arc Screen Provided on Turntable
Ø Light Curtain Operator Intrusion Protection
1.8 Tregaskiss 500 Amp Air Cooled clamping Torch
Ø 500 Amp Air cooled torch
Ø Accurate and Durable gooseneck maintains a repeatable tool center point
Ø The thick-walled aluminum gooseneck resists bending during collisions.
Ø The sleek design improves accessibility into tight work zones
Ø The hand nut makes maintenance easy -no tools required for neck replacement
1.9 Turntable & Positioners – 3 Axis
Ø A-B Station Servo Indexing Axis
o Servo Positioner
o Main axis 180 index time of approximately 3.2 seconds
o Fully welded H-frame assembly connecting the headstock and tailstock section for rigidity and long term repeatability
o 120mm through hole on main axis for utilities passage
o Arc screen rotates with the h-frame and tooling (user provided)
Ø Outboard Positioners (2)
o Panasonic Servo Positioners
o 550-lb capacity per side (see manual for loading details)
o 55mm through hole on outboard positioners for utilities passage
o Headstock to tailstock length of ~60″
o Rotation diameter of ~40″
o All axis fully servo driven, not limited to indexed positions
o Servo-disconnect technology to comply with latest safety standards. Removes power to outboard (operator side) servo when the light curtains are breached
Ø Remote Jog option included
o Allows the operator to safely rotate the load side fixture during normal operation
o Typically needed when an operator needs to load parts in more than one load position
1.11 Task Lighting (Operator and Robot Station)
Ø Fluorescent lighting at the robot and operator station to provide lighting during load/unload, inspection and programming
1.12 Harmony Software
Ø This option allows the robot and the servo positioner to work together in harmony.
Ø Sometimes called – coordinated motion – the result is that the robot can turn the part in the positioner at the same time the robot is moving and welding, whether the part is on-center with the positioner or not.
Ø The robot will maintain a consistent speed and path relative to the turning part.
Ø If you need to rotate your part while the robot is welding, this option is strongly recommended.
Ø Part number YA-1UPHA1
1.13 TREGASKISS REAMER with Sprayer, Wire Cutter, Lubricator
o Sprayer reservoir
o Simplified internal wiring by way of a centralized terminal strip
o Internally mounted pneumatic valves and protected external setup switches
o Features include a wire cutter, dedicated motor lubricator, anti-spatter sprayer, and nozzle reamer.
1.14 PerformArc 550HW FILTAIR Hood Only
Ø Stock #300965.
Ø FILTAIR fume hood when assembled and installed sits atop the PerformArc work cell.
Ø Spark cooler option sold separately.
Ø Assembly and installation of the fume hood sold separately. Permits, building modifications, assembly and installation or other extenuating requirements are the responsibility of the customer.
Ø Made from polycarbonate and light gage steel design.
Ø Patented source extraction rail technology which requires less air turnover to effectively capture welding fumes.
Ø Built in spark abatement.
Ø Fume capture zone spread over the work area, not a single extraction point.