Valk Welding: 1998

Valk Welding installed a Panasonic robot at Brabantia in Valkenswaard, integrated with an Engel-die casting machine. This vertical machine makes handles for tin openers. The robot positions little axles in a mould, after which the die casting machine produces the synthetic handle. The setting can work continuously for eight hours without any human interference.

Each time, the robot takes two small axles from a vibratory hopper and puts these in the mould. After processing in the die casting machine, the robot takes the two turning grips and moves them to the trimming unit. After trimming, the robot puts the handles on a tray. Then, the robot repeats this operation. When four end products are ready, any waste material is removed and a new cycle of again 27 sec.  can be started. All in all, the robot installation is about eight times faster than human hands, and a lot more accurate. The robot's gripper head is multi-functional. In total, the robot must be capable of taking up four different things: little axles, finished products, waste material and empty trays. Once the robot has filled a tray, it takes an empty tray from the stack and puts it next to the filled one. The robot picks up the trays with suction cups mounted on the head. In this way, the robot can fill two stacks of five trays. The little axles, the products and the waste material, are taken by the robot with five parallel grippers. A photo cell detects whether there is a product in the gripper. Return valves avoid that the material falls from the gripper when the pressure should suddenly drop. The Panasonic-robot is the heart of the installation, controlling the axle feeding, commanding the gripper and ensuring communication with the die casting machine. A digital connection has been provided between both appliances for communication. Via this connection, they signal each other whether a certain operation has been finished or not,  hence a perfect setting is of paramount importance for this system. A computer screen shows the exact phase the process is in. The computer can further be used to make programme back-ups and print-outs.

The robot application not only helps to increase the production speed and accuracy, but health risks in certain companies can also be pushed back. When for example spraying polyesters, noxious vapours may be released, and it is difficult to find personnel to do this job. Director Remco Valk rejects the suggestion that the use of robots is to the disadvantage of employment. "In periods of economic bloom, we often see that companies buy robots. They want to expand their production but they do not want to take the risk of hiring new personnel."

"The development of a robot installation takes some considerable time", Remco Valk stresses. "Of course, most companies want an installation than can be installed and commissioned in a short period of time. However, sometimes the processes involved have never before been done automatically. Before installing the final installation, the product know-how of the buyer and of the robot supplier should be evaluated regularly. For Brabantia too, this took considerable time. However, from the start parties had confidence in each other and in the robot capacity. And in the end, this has proven a solid base for a successful project." Valk Welding has become a big company with the assembly and sale of welding robots. The company claims to be market leader in the Benelux for robot systems and welding accessories. The last few years, Valk Welding  focussed more on horizontal growth. The expertise regarding integration of mechanic and electric systems can also be applied in other sectors.

(Source: Metaal & Kunststof - no. 1 19-01-1998)