KAWASAKI BA006L-A robotic welding cell

KAWASAKI BA006L-A robotic welding cell was built in 2021. The system is designed for fully automatic MIG/MAG arc welding. All the necessary equipment and machinery with the best technical specifications are integrated inside an enclosed, fully ventilated structure.

The robotic welding station consists of the following components:
– robot arm: KAWASAKI 3BA006L-AC01
– welding positioner: ASTOR PST250E-H1 (2 pcs.)
– MIG/MAG welder: FRONIUS TPS 400i
– wire feeder: FRONIUS WF 25i REEL R /4R/G/W
– push-pull drive unit: FRONIUS WF 60i Robacta Drive CMT/W
– cooling unit: FRONIUS CU
– welding fume extraction unit: KEMPER FilterCell XL (2 pcs.)
– light curtains: SICK
– fixed covers with safety switch

The machining process is performed by a KAWASAKI 6-axis robot, distinguished by its sophisticated design and robust arm with an increased range of movement. It cooperates with two positioners, enabling the machining of parts with even the most complex shapes. Each of the six axes is driven by powerful servo motors, delivering excellent dynamic movements combined with high process reliability. What’s more, a number of state-of-the-art systems ensure uninterrupted operation of the machine, without any downtime.

The entire workspace is ventilated from welding fumes by powerful KEMPER extraction units. The use of this solution significantly improves overall safety and comfort.

Technical specifications of the individual parts of the KAWASAKI BA006L-A welding station

Welding robot

• number of axes: 6
• maximum payload: 6 kg
• maximum arm reach: 2036 mm
• axis movement range

– JT1 axis: ± 165°
– JT2 axis: + 150° / -90°
– JT3 axis: + 90° / -175°
– JT4 axis: ± 180°
– JT5 axis: ± 135°
– JT6 axis: ± 360°

• axis motion speed

– JT1 axis: 210°/s
– JT2 axis: 210°/s
– JT3 axis: 220°/s
– JT4 axis: 430°/s
– JT5 axis: 430°/s
– JT6 axis: 650°/s

• positioning repeatability: ± 0.08 mm
• mounting: floor, ceiling
• ambient temperature: 0-45°C
• relative humidity: 35-85%
• weight: 160 kg

Welding positioner

• maximum payload: 250 kg
• number of axes: 1
• axis movement range: ± 360°
• maximum axis rotation speed: 180°/s
• axis height: 131 mm
• maximum distance from centre of gravity to axis: 105 mm
• positioning repeatability: ± 0.05 mm
• maximum bearing bending moment: 784 Nm
• maximum torque: 612 Nm
• nominal torque: 245 Nm
• maximum moment of inertia: 41 kgm2
• ambient temperature: 0-40°C
• weight: 40 kg

MIG/MAG welder

• mains voltage: 3x 400 V
• mains frequency: 50-60 Hz
• maximum welding current: 400 A
• minimum welding current: 3 A
• welding current at 40°C (40%/60%/100%): 400/360/320 A
• idle voltage: 75 V
• MIG/MAG operating voltage: 14.2-34 V
• touchscreen display with personalised menu in more than 30 languages
• water cooling
• degree of protection: IP23
• dimensions (L x W x H): 706 x 300 x 510 mm

Extraction unit

• capacity: 1000 m3/h
• maximum compressed air pressure: 6 bar
• minimum compressed air pressure: 5 bar
• power supply: 3x 400 V; 50 Hz
• weight: 135 kg