Three additional welding cells ordered by Crown Equipment

Citation

(1999), "Three additional welding cells ordered by Crown Equipment", Industrial Robot, Vol. 26 No. 4. https://doi.org/10.1108/ir.1999.04926daf.001

Three additional welding cells ordered by Crown Equipment

Three additional welding cells ordered by Crown Equipment

Keywords Welding, ABB, Robots

ABB Flexible Automation has supplied additional robot welding cells to Crown Equipment to expand their production capacity and upgrade existing facilities at the company's plant in Galway on the West Coast of Ireland. The new cells form part of an automated production line for hand operated pallet trucks (see Plate 1).

Plate 1 ABB welding robot in operation at Crown Equipment

Pallet trucks are used throughout industry and whilst demand is constant, it is a fiercely competitive market with the emphasis on price and the finished product quality. By investing in advanced manufacturing technology Crown Equipment has secured its place as a leading manufacturer. A large proportion of its output is shipped to the USA and the rest go to customers in the UK and Europe.

In addition to hand operated trucks, Crown Equipment also produces an electric powered "walkie" truck and a series of more specialised narrow isle lifting equipment/stacker trucks.

Output of pallet trucks from Galway has grown steadily over four decades to reach its current level of several thousand a month. Production methods have been updated progressively during this time. Robot welding was introduced in 1986 and other complementary developments have followed including the use of advanced CNC punch presses and sheet metal forming machines to improve the dimensional accuracy of component parts.

"We have decided to open a second line for the production of hand operated pallet trucks in Galway in order to achieve the maximum return on the capital investment", explains project engineer Martin O'Neill.

Robots are used to MIG weld all the structural components, the push rods and the hydraulic pump housing. Having started as one of Ireland's pioneers in the use of robot technology, Crown Equipment has developed its own in-house capability with qualified engineers able to take full responsibility for maintaining the welding cells.

Even so Martin O'Neill recognises the value of a close working relationship with ABB Flexible Automation. Counting the new installations, Crown Equipment now operates 13 ABB robot cells, most of which are in use almost continuously 24 hours a day.

"We have built our experience around ABB welding systems and now have examples of all three generations of controllers, from $2 to $4, currently in service. The new robot cells are based on the latest Arcitec system, which has a combined controller and welding power source and takes up less floor space. Prior to delivery each of the new cells was set up and checked-out at Milton Keynes using tooling and test pieces supplied by Crown Equipment".

"We expect ABB to be competitive and we chose Arcitec because we are confident the system will continue to deliver good performance and reliability. From our knowledge of robot technology we can fully evaluate the benefits of new developments such as ABB's Bullseye calibration facility, which will allow us to achieve greater consistency in our quality standards", he said.

The entire manufacturing operation is housed within a modern 160,000 sq. ft factory building. Starting with steel sheet in coil form, the forks and truck apron components are punched out, formed and fed through into the welding cells. Each of the robot cells is equipped either with a turntable or a servo driven manipulator for speed and flexibility.

Production is based around a flow line with supporting cells for other parts requiring subsequent machining operations, such as the housing for the hydraulic pump. On completion, the welded truck frame and components are washed prior to finish treatment, powder coating and final assembly.

For further information contact: Jane Attwood, ABB Flexible Automation Limited, Auriga House, Precedent Drive, Rooksley, Milton Keynes, MK13 8PQ. Tel: +44 (0) 1908 350300; Fax: +44 (0) 1908 350301.