FANUC Arc Mate 120iC/12L robotic welding station

FANUC Arc Mate 120iC/12L robotic welding station was built in 2016. This system enables fully automatic welding of workpieces using MIG/MAG and TIG methods. The machining process is performed by a reliable industrial robot, which, in combination with two positioners, enables the machining of parts with even the most complex shapes.

The robotic welding station is fully complete and consists of the following components:
– robot arm: FANUC Arc Mate 120iC/12L
– controller: FANUC R-30iB
– welding positioner: PEH 1-250 (2 pcs.)
– welder: LINCOLN POWER WAVE S500
– liquid-cooled welding torch: ABICOR BINZEL ABIROB W500/45
– cooling unit: LINCOLN COOLARC 50
– welding torch cleaning station: ABICOR BINZEL BRS-CC
– wire feeder: LINCOLN 4R100 AUTODRIVE
– welding wire reel cassette
– light curtains: SICK
– operator’s panel (2 pcs.)
– control cabinet
– covers with service door and lock with safety switch
– platform

The FANUC M-20iA/12L 6-axis robot has a well-thought-out design and a number of systems to ensure uninterrupted operation without any downtime. In order to avoid possible collisions of the welding cables with other station components, they have been routed inside the arm of the FANUC robot. Moreover, additional function packages allow, among others, a very precise determination of the sensitivity of the collision detection system and, therefore, the exclusion of accidental false stops of the machine.

Each of the six axes is driven by high-performance servo motors, which significantly reduce the production time of individual workpieces by shortening the travel time between welds. The welding torch is cleaned continuously by an ABICOR BINZEL cleaning station, which injects inside it a special substance to prevent sticking. The cleaning and wetting process is performed automatically at defined intervals.

Technical specifications of the individual parts of the FANUC Arc Mate 120iC/12L welding station

Welding robot

• number of axes: 6
• maximum payload: 12 kg
• maximum arm reach: 2009 mm
• axis movement range

– J1 axis: ± 370°
– J2 axis: ± 260°
– J3 axis: ± 461°
– J4 axis: ± 400°
– J5 axis: ± 360°
– J6 axis: ± 900°

• axis motion speed

– J1 axis: ± 200°/s
– J2 axis: ± 175°/s
– J3 axis: ± 190°/s
– J4 axis: ± 430°/s
– J5 axis: ± 430°/s
– J6 axis: ± 630°/s

• motion repeatability accuracy: ± 0.008 mm
• package Collision Guard Package
• package High Sensitive Collision Detection Package
• anti-collision system
• weight: 250 kg

Horizontal welding positioner

• number of axes: 1
• maximum workpiece weight: 500 kg
• work area (L x W): 2000 x 1000 mm
• distance between discs: 2620 mm
• positioning repeatability: ± 0.15 mm
• disc rotation speed adjustment: servo drive
• disc rotation drive: electric
• power supply: 3x 400 V; 16A
• dimensions (L x W x H): 3533 x 540 x 898 mm
• weight: approx. 1000 kg

Welding source

• power supply: 3x 230/400/460 V; 50-60 Hz
• maximum current (40%/100%): 550/450 A
• dimensions (L x W x H): 571 x 355 x 630 mm
• weight: 68 kg

Welding torch

• maximum wire diameter: 1.6 mm
• minimum wire diameter: 0.8 mm
• tilt angle: 45°