To increase productivity and reduce repetitive tasks and manual work, Danfoss wanted to remove a manual welding station from their production. Eltronic’s solution was a cobot that could be quickly and easily integrated into the existing production line.
One of things that were important to Danfoss when presenting their requirements to Eltronic was that the new station would, so to speak, be able to take care of itself. Operators would be able to feed the new station with work items, but otherwise manual work had to be reduced to an absolute minimum.
Other requirements were operator safety, fast integration into the existing production line and operational flexibility.
A coworking robot
The solution presented by Eltronic was a collaborative robot. One of the advantages of using a cobot is that it is easy to implement in an existing production as it requires a minimum of training and no shielding. Furthermore, cobots are designed to cooperate with people and they are therefore safe to use and easy to feed with new components.
All operations are performed with a maximum degree of accuracy and safety. Operators are only needed to feed the cobot with items and to change variant. If they come too close, the cobot automatically moves or stops the current operation.
Increased flexibility at reduced cost
The cobot integrated at the welding station at Danfoss assembles two parts (pipe and ring) and prepares the components for welding by dipping the assembly into a liquid before moving it to the welding machine.
The tools are easy to replace and the cobot automatically detects when the tool has been changed. The cobot is able to handle multiple variants and in case of a stop, it is easily reactivated by pushing a button.
To increase productivity and reduce the manual and repetitive work performed at a welding station.
- Able to interface with existing welding machine
- Fast implementation into existing production line
- Able to handle multiple variants of tubes and welding rings
- Reduction of operator involvement
- Operator safety
- UR5 Cobot
- Robot and tools sensitive to impact
- AnyFeeder solution for feeding welding rings
- Cartridge-type tube trays loaded by the operator
- Liquid level detection by the cobot’s tool sensor
- "System-on-a-plate" – easily integrated with existing welding machine
- Manual change of tools with automatic tool detection
- Reduced operational costs
- Short payback time
- Elimination of repetitive and manual processes
- Complete operator safety
- Flexible - easy change of tools
- Almost immediate integration into existing production line
Danfoss engineers technologies that enable the world of tomorrow to do more with less. Danfoss' products are used in areas such as refrigeration, air conditioning, heating, motor control and mobile machinery. Danfoss is a world-leader employing more than 25,000 employees and serving customers in more than 100 countries.
This is the first Collaborative Robot (Universal Robot) that we have implemented in our Kolding Factory. The main driver of the project was to get a common understanding of what a collaborative robot is, throughout the whole organization. Especially between project management, production technology, operators and the safety department. That part of the project has been a big success, and everyone have a good feeling on Collaborative Robot solutions.
The robot is implemented and operate in the same area as the operator and takes over some of the physically stressed processes from the operator. We don’t have any other safety devices than the safety system in the robot itself.
To give us some input on the safety issues regarding collaborative robot solutions we had a meeting at Eltronic where we had invited Teknologisk Institut as a facilitator. That gave us, and Eltronic, a good idea on how to make a Risk assessment on these solutions.
Peter Lundø Hansen
Senior Project Manager, MT Project Region EMA