Panasonic Factory Solutions has implemented its TAWERS G4 welding robot system for STADLER Anlagenbau, a manufacturer of special systems for turnkey recycling and waste sorting plants. This automates manual welding processes, significantly reduces welding cycle times, and increases the efficiency and scalability of the production line.
Reduced cycle times are a priority
Since all systems and components are manufactured in-house, STADLER currently uses G3 systems from Panasonic to control all welding work on the conveyor frame system, the pre-assembly, and the actual assembly. The integrated welding source, the wide process range (MIG/MAG, Puls-MAG, CO2), and Panasonic's intuitive Weld Navigation software provide high flexibility while maintaining consistently stable quality.
The new G4 Welding Robot System optimizes the welding process management in a single control for high-quality arc welding. It features improved control computing power, higher axis speeds, and optimized communication between control and robot. The high-resolution touchscreen of the G4 facilitates programming with enhanced contact tips that provide excellent welding quality and reliability.
This eliminates the need for a larger spare parts inventory and minimizes downtime during maintenance.
Before installation, STADLER conducted extensive simulations and test weld seams at Panasonic's Robot & Welding Test Center in Neuss. Employees received expert training to optimally utilize the functionality of the G4.
“The welding robot systems from Panasonic are easy to use and maintain. As a result, the cycle and throughput times for some products, including all preparation, have been reduced to one third of the original time. With planned maintenance cycles, the G4 has proven to be absolutely reliable since its installation. Support is always quick to respond to any questions, providing us with security,” says Bruno Stützle, Production Manager at STADLER.
Virtual production planning and simulation
STADLER uses Panasonic's offline software for desktop programming and simulation (DTPS) throughout its production line. This allows digital remote access to the production and operational data of the plant in real-time and enables simultaneous planning and simulation of manufacturing processes. This increases flexibility in production and saves valuable time and resources.
DTPS can also input CAD data directly (in various formats) into the production line. Component geometries can be easily adjusted, while functions such as collision detection, cycle time calculation, and welding parameter optimization further improve quality and efficiency.
“Thanks to Panasonic's offline programming software DTPS, we can simulate and optimize production processes already in the planning phase. This saves time and reduces the risk of errors and necessary rework,” adds Stützle.
A gateway to global expansion
By acquiring a third TAWERS welding robot system, STADLER was able to significantly increase its production efficiency. This provides the company with the scalability to expand internationally into new regions and explore new business opportunities in the areas of e-waste and clothing recycling.
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