Price: $78,000 F.O.B. Longview, Texas
The Robotic Polishing cell is made up of several components that are integrated together. We used the cell to polish 3" diameter 304 stainless steel tubes from a mill finish to a mirror finish. The tube was a step bar below the doors for pickup trucks and SUV's. Attached is a photo of the polishing application. We polished the tube 360 degrees, tube lengths and leg lengths varied with models. We had two fixtures to support the tubes that were position 90 degrees apart. The operator would unload a polished tube, load and prep one tube while the other tube was being polished; cycle time was 6 minutes per tube on the Robotic Cell, manual polishing required 20 minutes per tube.
1. Robot, Kuka KR150L 150/3, capable of carrying a payload of 330 lbs, a reach of 102" fully extended in each direction, with a positioning accuracy of + or - .008". The robot is controlled by a Kuka KRC1 controller and utilizes a PC based Pentium processor and runs Windows 95 software. The MEP (main electrical panel) includes a main disconnect, servo motor drives for the 6 axis of robot movement and the PC Pentium processor, hard drive and floppy drive. Included in the MEP we added Wago digital and analog inputs and outputs modules to control other components. The manual and setup modes are controlled by a handheld KCP operator's pendant. Attached is a photo of the Robot with a servo driven spindle that rotates a 10" diameter stack of polishing wheels at 10,000 surface feet per minute. Positioned above the wheel is a spraying nozzle that sprayed liquid polishing compound on the wheels while polishing occurred.
2. The servo motor is a Parvex HV840EMR8000, 460/3/60, 10.3KW, 3060/8000 RPM and it is driven by a Digivex 50 amp power supply with encoder feedback. Attached please find motor specifications, solid model drawing and dimensions of the motor support and wheel assembly.
3. The abrasive spray system consisted of a 55 gallon of liquid abrasive compound, a Graco air operated pumping system (not included with the Robotic Cell) and a Widoberg spray nozzle that sprays the liquid abrasive on the wheels. The Widoberg spray nozzle can supply up to 2000 psi of pressure to apply abrasive to the wheel surface.
4. Force control system was supplied by Amatec. Amatec was owned by Kuka. The system consisted of a load cell, that was added between the robot wrist and servo motor to monitor the force and software that monitored the force between the wheel and tube and automatically increase the force in one axis as the wheels would wear. The software allowed for a window of force to be maintained and this resulted in a uniform mirror finish. This system is compatible with KRC1, KRC2 and KRC3 controllers and included FTCtrl software license, controller card, cables and utilizes ATI transducer for monitoring force.
We purchased the Robot in 2002 and integrated the various components in 2003 and 2004. I would suggest you contact Kuka and upgrade the KRC1 control and KCP Pendant to current models.
Price: $72,000 F.O.B. Longview, Texas
Year 2003, Installed 2005
Weight 800 Lbs (Robot Only)
Robot - 6 Axis Welding 3 Phase, 440V
Range of Movement (in degrees)
Axis 1- +180 to -180 Axis 2- +110 to -100
Axis 3- +65 to – 60 Axis 4- +185 to -185
Axis 5- +115 to – 115 Axis 6- + 400 to - 400
Automatic tip cleaning
Rotary Index Table
Auto Calibration System
Welder, 450 amp at 100% duty cycle. Miller Invasion II, pulse welding capable, Serial # LC-691799
Power on hours 7,106, welding hours less than 1500.