What does VIRS do - as a robot integrator?
For example, if a car crane manufacturer needs a new production system, it needs to consider many things to keep all the components running smoothly and in a coordinated manner, in the right order and with the right procedure. An important role in this is played by robots, both manipulative, which position the parts in the optimal position, as well as welding robots and welding machines, which combine the individual components into a functional unit. Coordinating all system components is a very specific and responsible task. The manufacturer often leaves this to a specialist: ROBOT INTEGRATOR.
At Virs, as robot integrators, we analyze with you the needs of the production process, prepare a robotization plan and introduce it into your production. Depending on the needs of the application, we determine the appropriate robot cell, advise on time and cost savings, take care of the programming of the robotic system and introduce it into the customer's production process.
''We offer a complete package of solutions: from an idea to its integration, at the same time we educate and offer repairing services. At the customer's request, we can also participate in the introduction of a robot cell into the production process. The customer thus saves time and benefits from many years of experience and knowledge of our experts. All this is done in close cooperation with the customer! With our solutions, we optimize work processes, protect valuable workforce and increase productivity, '' said Vladimir Magdalenić.
How do we tackle the project?
A successful integration of robots requires a high level of coordination and knowledge. Each partner, to whom we integrated a new solution into the production process, benefited from the rich experience of our project team, which consists of mechanical and electrical designers, development engineers, machine engineers and robot programmers.
We start each project with careful planning and as integrators pay special attention to achieving:
- maximum level of quality,
- reliability of operation and
- optimal cycle time.
Each system is unique and we perfectly adapt it to the customer's requirements. Understanding and transparency of the customer's requirements is extremely important in the planning process itself. The appropriate approach, however, varies by industry.
In the automotive industry, with which we have quite a bit of experience, there is a special specification called the applicant, in which the customer defines in great detail all their requirements, which represent the starting point for the preparation of a draft solution. At the same time, our customers additionally answer questions about:
- existing hardware
- security systems
- required system capacity
- user interface requirements, etc.
because on the basis of the most detailed and comprehensive information, it is easier to set up and present the final solution to the customer.
The situation in the metalworking industry is different for each branch, so we help customers in different branches to set and define specific requirements. Only then we propose the optimal system. We almost always solve our customers' very specific problems that require the most "crazy solutions", which neither the customer nor we have implemented before. Challenges that are very complex further motivate our team.
How does a robotic system start up?
Expert Vladimir Magdalenić explains that the entire robotic system was first set up in our production facilities. Throughout the assembly and programming of the robotic system, the customer has the opportunity to monitor the process from the creation to the introduction of the system into its production.
In the presence of their welding technologist, a test welding is performed. This is followed by installation and commissioning at the customer's premises. Proper setting of welding parameters on site requires from us quite a bit of programming experience, knowledge and also a feeling that the required quality of the welding process can be achieved. We are implementing in the majority of the solutions our software application "WeldCockpit."
The application WeldCockpit enables monitoring and documentation of technical and economic parameters in automated and robotic welding, according to the criteria of Industry 4.0. With the application, we can systematically monitor and maximize production in robotised factories.
For the smooth operation of the robotic system, it is crucial that the employees who manage the robotic system at the customer are properly trained. Of course, we are still available for advice, support and service even later. At the customer's request, we also offer assistance in starting production with a robot.We are considered a system partner and not just an equipment supplier!
Welding tests to ensure quality
The success of welding, which is considered a complex process, in practice depends on many factors. In projects where we use new welding procedures or special materials, we pre-perform test welding with welding equipment from renowned world manufacturers of welding equipment.
Why is it important to choose a good welding machine?
When choosing welding machines, we pay special attention to the welding system being easy to use - this applies to parameter setting as well as maintenance. In robotic applications, it is also important that the tool point (TCP) is stable, adds our expert.
Tool Point (TCP):
By default, it is located in the middle of the flange of the sixth axis of the robot. In the case of a tool on the sixth axis (in our case it is almost always a welding burner), it moves to the starting point of the tool (welding nozzle). This can be approximately in the middle between two gripping fingers or at the top of the welding wire or TIG electrode at the welding robot. The TCP point is considered to be the most important reference point for programming robot operations.
If the burner collides with a component and the components move only slightly, this point must be reprogrammed. The welding equipment that we integrate into our robotic systems also has a magnetic CrashBox added if necessary, which immediately reduces the load to a minimum in the event of a collision, thus preventing damage to the burner and other parts.