KN Tech

Background

Application to brazing welding

The reason for considering a welding robot for brazing this time was a request for a brazing welding job from a motorcycle manufacturer with whom we have a business relationship. Braze welding is a type of brazing and is a welding method used mainly for parts such as tanks and parts of fueling ports. The features of brazing welding are that it can join at relatively low temperatures compared to normal welding, thus minimizing deformation of the workpiece, and it can easily be applied to thin plates and fine parts. 

"When welding tanks, we are particularly careful about the quality of the workpiece, because if quality defects occur on the underside of the bead due to excessive heat input, there is an increased risk of rust. This led us to consider purchasing a welding robot that could weld under uniform conditions."
(Managing Director Yuichiro Nakayama)

Reason for introduction

Existence of dedicated brazing welding software

Panasonic welding robots have a dedicated brazing software option, and this was the most decisive factor. In the past, KN Tech's welding conditions were set by veteran employees based on their experience, but in anticipation of future handover, the ideal was to be able to set conditions without relying on human operators as much as possible.

Low spatter generation

KN Tech had been using robots from other companies besides Panasonic, but the low spatter of Panasonic welding robots was also an important factor in their selection. The spatter removal process was the easiest part of the process. In the past, we had to remove spatter while the robot was in motion. The spatter removal process is quick for those who are accustomed to it, but for those who are not accustomed to it, it takes a long time. With Panasonic robots, this process is much shorter. 

Post-introduction effects

High-quality brazing without relying on human resources

The dedicated brazing welding software makes it easy to set up difficult brazing conditions.
Using the dedicated brazing welding software has made condition setting and adjustment much easier. Although some modifications are necessary after the software is applied, the time required to set the conditions has been greatly reduced compared to the past.

Experience reliable wire feeding and stable robot operation

While other companies' robots have sometimes caused equipment stoppages due to feedability problems during long work periods, Panasonic's robots rarely have such problems, resulting in less lost work time. They move very quickly. And the control is very tight. The beads are stable. 

"I really appreciate that.The production volume is completely different, and if we run the line for a day or a week, the production volume is different, so both the shop floor and I are fully aware of the effects of this."

Significant reduction in work time

Since its introduction, we have seen significant benefits. In particular, the welding process time has been greatly reduced, from 120 seconds to 85 seconds.
In addition, the generation of spatter has been greatly reduced, and the labor and cost of its removal has also been drastically reduced. Improvements in quality, strength, and appearance are also evident, further enhancing the quality of the product.