The TAWERS welding technology WGH integrated by Panasonic Factory Solutions was implemented by the automation specialist ERL for the German manufacturer Hopf GmbH. This is a key feature of ERL's ARCentre XPERT welding robot solution, which combines the robot controller and the welding power source into a single platform.
Greater precision and reduced downtime
To maximize welding quality, production efficiency, and capacity in response to increasing production demands, the solution includes:
• Automated torch cleaning that ensures a constant welding function and reduces downtime.
• Integrated cooling technology that protects critical components from wear and extends their lifespan.
• Panasonic's TouchSensor and ARCSensor technologies automatically compensate for workpiece tolerances and thermal distortions during welding. This consistently delivers precise weld seams with a repeatability of 0.1 mm.
Increased productivity and process stability
The solution performs MIG/MAG welding using standard, pulse, and special pulse processes, enabling support for a wide range of applications. Two configurable workstations allow operators to efficiently process different component types, with driven positioning systems handling workpieces of up to 500 kg to ensure consistently precise weld seams.
The solution includes an approximately eight-meter travel path for the WGH robot, maximizing reach and flexibility. A Rolliner wire feeding system has also been implemented for smooth and reliable wire supply. This reduces wear and minimizes maintenance needs as well as downtime associated with frequent wire spool changes.
Seamless digital production planning
The ERL solution also includes Panasonic's Desktop Programming & Simulation (DTPS) software. This offline programming platform allows Hopf GmbH to virtually plan, simulate, and optimize welding tasks before production begins. Operators can conduct accessibility checks, collision monitoring, and welding cycle analyses while creating and modifying welding programs.
The software also supports the import of CAD data and includes Panasonic's Welding Navigator functionality, which helps optimize programming and accelerate production start-up. Overall, the automated ARCentre XPERT welding robot solution has already significantly increased productivity and welding quality, reduced manual workload, and simplified process management.
“Since the commissioning of the ARCentre, our productivity has significantly increased,” comments Engelbert Hopf, Managing Director of Hopf GmbH. “Repeat orders are particularly well suited for the system, as they can be produced very quickly with minimal preparation and programming work.”
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