Boost Your Productivity

Transcription

1 Boost Your Productivity

2 2 Askaynak Automation

3 Askaynak Automation Efficient Competitive Safe! Askaynak Automation is a fully-owned subsidiary of Eczacıbaşı-Lincoln Electric Askaynak, the leading supplier of welding consumables and equipment in Turkey and an equal share joint venture with the Lincoln Electric Company the world leader in the design, development and manufacture of arc welding products and equipment, robotic welding systems, plasma and oxyfuel cutting equipment. Soon after, the company expanded its field of activity to the welding and spot welding industries, where it began to collaborate with Eczacıbaşı- Lincoln Electric Askaynak on robotic welding applications. In 2014, Askaynak Automation became a fully-owned subsidiary of Eczacıbaşı- Lincoln Electric Askaynak, with the aim of becoming a powerful regional supplier of engineering services. Askaynak Automation was established in 2002 as SYS Robot Technologies to provide automation solutions for the automotive industry. Initially, the company focused on manufacturing equipment designed by customers, then turned to designing equipment in-house, including molds, fixtures, face molds and special purpose tools. In 2004 Askaynak Automation signed a distribution agreement with Toshiba Machine, and in 2007, an integrator agreement with Fanuc Robotics. 1

4 2 Askaynak Automation

5 Why Askaynak Automation is The Right Choice For You? 250 SYSTEMS THROUGHOUT TURKEY AND SURROUNDING COUNTRIES Robotic automation systems help to ensure uniform product quality, cleaner and faster manufacturing, and lower labor costs. Since its establishment, Askaynak Automation has specialized in applications where human error is frequently observed. Solutions for such critical applications as welding and painting enable customers to combine more efficient manufacturing with high precision by minimizing manufacturing defects caused by human error. To date, Askaynak Automation has developed and installed more than 250 robotic automation systems solutions in Turkey and surrounding countries for painting; MIG/MAG, TIG, spot and laser welding processes; machine tending; and welding mechanization. Robotic Applications Robotic MIG/MAG Welding Robotic Spot Welding Robotic Laser Welding Robotic Painting Robotic Machine Tending Welding Mechanizations Fixture Design (for Robotic Applications) 3

6 4 Robotic MIG/MAG Welding Applications

7 Robotic MIG/MAG Welding Applications WE DESIGN OUR SYSTEMS TO THE FINEST DETAIL MIG/MAG welding is a process that seems simple but requires specialization because of its varied components and the many errors that can occur. The development of industrial robots for MIG welding requires four different areas of expertise: advanced welding knowledge, specialization in robotic equipment, special fixture design, and manufacturing knowledge. As a subsidiary of Turkey s leading supplier of welding consumables and equipment, we are able to offer highly effective turn-key solutions that combine Askaynak s know-how in welding with our expertise in robotic equipment. Our development process for robotic MIG/MAG systems entails each of the following steps: 1) Checking material weldability 2) Calculating weld size and welding periods 3) Determining production speeds and robot sequence 4) Simulating robot reachability 5) Selecting a basic fixture structure 6) Ensuring alignment with rigorous OHS standards 7) Submission of solution proposal 5

8 6 Robotic Spot Welding Applications

9 Robotic Spot Welding Applications SIMPLE, FAST AND PRECISE SPOT WELDING WITH ROBOTIC TECHNOLOGY Many years of experience in the automotive industry have given us a unique expertise in the development of user-friendly robotic spot welding systems that maximize productivity and occupational safety. HOW WE WORK? Robotic spot welding applications are used extensively, especially in the automotive industry. Because the automotive industry requires high production rates and faultless production, new robotic spot welding equipment is continually being developed. However, the high mass of system geometries and geometric features of parts to be welded make the robotic spot welding process particularly hard to design. To this end, we create highly flexible and productive systems that utilize the full capacity of robots and equipment through precise design and assembly. For standard robotic spot welding applications, we calculate welding periods using simulations of design prototypes to get very realistic projections. We also enhance the reachability of spot welding guns and minimize potential risks by designing fixtures into the system. Before preinstallation and testing, we evaluate our technical designs with customers to ensure optimum environmental health and operator-equipment safety. 7

10 8 Robotic Laser Welding Applications

11 Robotic Laser Welding Applications LASER WELDING IS NO LONGER A FUTURE TECHNOLOGY! Laser welding is widely used for repair weld and manual welding of thin materials. Laser welding has become increasingly popular in large-scale production as materials become thinner and the demand for a clean/ decorative appearance increases after welding process. PRECISE DESIGN ENSURES CORRECT RESULT Laser welding is more difficult than other mass production methods because it requires qualified welding personnel and careful preparation of precision parts. After studying the preparation of parts, Askaynak Automation determines the system and fixture needed for a standard robotic laser application and submits a feasibility report. If the system is approved, the project enters the design and pre-production stage. We then test the initial design of the system and fixture structure with customer s existing parts. If these tests indicate any problems, we revise the system and test again. The last stage of the project is operator training; when this is completed, your system is ready for operation. 9

12 10 Robotic Painting Applications

13 Robotic Painting Applications CONSISTENT PAINT QUALITY Every year, the demand for robotic painting increases as companies seek to improve paint quality and reduce employee exposure to potentially hazardous substances. Specializing in three different fields of the robotic painting process, Askaynak Automation is well-equipped to design and install these systems in any industry, particularly the automotive industry. During the design of a painting system, we calculate the time it will take using simulations based on the geometry of parts to be painted. Thanks to our computer-aided online programming, we enable customers to minimize system shutdowns on large-scale production lines by cutting run-up periods by half. During the start-up stage, we examine the surface quality of parts with our customers to ensure that they meet the standards required for robotic painting. We then carry out test runs on all the parts until we obtain the calculated painting speeds. During the design stage, we calculate ventilation and protective covers for robotic arms and calibrate the system accordingly. 11

14 12 Robotic Machine Tending Applications

15 Robotic Machine Tending Applications HIGHT PRODUCTION SPEED IN DANGEROUS AREAS We want to help you achieve efficient large-scale production without delays, human error and occupational accidents. Our advanced systems increase your manufacturing capacity while reducing manpower, this way facilitating a rapid return on investment. LOWER LABOR COSTS AND RAPID RETURN ON INVESMENT CNC controlled machinery has replaced manpower in the lathe, milling, and injection processes; aside from programming, labor is only used in the loading/unloading of parts. Now, operations involved in large-scale production are looking for ways to eliminate the human factor in this simple, repetitive task. Askaynak Automation develops systems that maximize productivity with minimum labor. By removing labor from production space, machines can be moved closer together and integrated in a conveyor belt system that uses loading/unloading robots. To minimize the time needed to load and unload objects and ensure continuously flowing lines, we analyze the specific parts involved in manufacturing and design special grippers accordingly for robots. 13

16 14 Welding Mechanization

17 Welding Mechanization UNIQUE DESIGNS FOR DIFFERENT NEEDS Robotic automation may not provide solutions for some heavy industry needs, such as intensive submerged arc welding in steel construction, pressure vessel manufacturing, and spiral pipe welding. For these applications, we supply custom designed solutions involving column and boom manipulators, positioners, rotators and storage tank welding machines that are user friendly, durable, and easy to repair. We are also able to add welding parameter imaging and saving features that facilitate instant monitoring and back checks of welded connections to prevent errors. 15

18 16 Fixture Design and Production

19 Fixture Design and Production PERFECTLY DESIGNED FIXTURE IS THE CORE OF AUTOMATION! Smoothly operating robotic systems require that every part in the manufacturing process always has the same coordinates. Hence, fixtures, or fastening devices, are central to the efficient operation of all automated processes. Askaynak Automation designs fixtures to the specific needs of each process and manufactures them in-house with an expertise derived from many years of experience in this industry. To ensure the optimum result every time, we carry out simulations of fixture design with its intended robotic cell to check for measurement-geometric errors that might prevent the robot from operating smoothly. If any adjustments in design are required, we make them before manufacturing begins. To ensure the longest fixture lifetime possible, we select all parts from proven brands. All these measures help to prevent losses during manufacturing from faulty measurement. 17

20 Design Process and Engineering Approach DELIVERY and INSTALLATION 5 PROJECT DEVELOPMENT 4 1 PRELIMINARY ACCEPTANCE DESIGN and ANALYSIS 3 MANUFACTURING PROCESS 2 18

21 Design Process and Engineering Approach PROJECT DEVELOPMENT During the project development phase we listen to your needs and analyze your manufacturing process. After obtaining all required information, our project manager presents the optimum solution for your specific manufacturing parameters. Once an agreement has been reached on technical and commercial matters, the project is transferred to our design team. DESIGN and ANALYSIS PROCESS The design process encompasses all aspects of a system s mechanical and electrical design. After the completion of technical drawings, we evaluate critical values, such as required reachability and mechanical load, using a variety of analytical tools and simulation techniques. This is the phase where we also design customized parts, such as positioners, sliders and bases. If the new system is similar to an earlier one, the design process is completed more quickly. MANUFACTURING PROCESS After the design and analysis processes are completed, we start to manufacture the system s mechanical parts, assemble the robots, and install the required electrical-electronic infrastructure. We also manufacture the fixtures for robots during this stage. When the system is completely assembled, we execute a series of functional tests. PRELIMINARY ACCEPTANCE Once the system has passed our functional tests, we begin pre-production tests. This is the phase where we can make minor adjustments and ensure that the system operates as originally designed. Once you give your preliminary approval to the system, we provide extensive training to your operators at our plant. DELIVERY and INSTALLATION After the preliminary acceptance process is completed and we have trained your operators, we install the system in your plant. There, we test the system once again with your operators. During this phase, we also provide additional training on how to prepare parts for robotic automation and repair-maintenance. When this is done, and we have your official approval, delivery of the system is finalized. 19

22 Our References П С К Группа компаний ПромСтройКонтракт 20

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24 ASKAYNAK KAYNAK TEKNİĞİ SANAYİ ve TİCARET A.Ş. TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi 2. Cadde, No: 5, Şekerpınar Çayırova - KOCAELİ - TURKEY Tel : ( ) Fax : ( ) automation@askaynak.com.tr Art. nr. 01/12/ BeyazAjans/SerhatA/CanO