Robot cell from KUKA Systems shapes parts assembly
KUKA Systems UK has played a key role in developing an automated cell for a major research project into bulk additive manufacturing. The automation solutions specialist worked with research engineers from the Nuclear Advanced Manufacturing Research Centre (Nuclear AMRC) at Sheffield University to design a 10x5m robot cell for building near net shape parts from the ground up as well as add metal features to large structures.
The cell comprises a 6-axis KUKA robot, mounted on a 3-axis, 5m high gantry, and a 2-axis manipulator with 3.5m diameter turntable. The robot arm is equipped with a TOP TIG arc welding system that integrates the wire feed into a welding torch.
The robot works directly from a CAD model to lay down weld material to create 3D geometries and add non-critical structural features to structures such as large pump and valve casings or pressure vessels. In addition, the robot can carry a variety of end effectors, which enable the research team not only to potentially deploy a range of welding techniques using metal powder and wire, but also inspect and finish parts in a single set-up.
The project, funded by the High Value Manufacturing Catapult, is designed to show how additive manufacturing can be more easily introduced into existing production lines. It stemmed from KUKA’s previous involvement in building a small shaped metal deposition cell that was originally supplied to Rolls-Royce and later moved to the Nuclear AMRC facility.
Dave Burns, KSUK’s project sales engineer, explained: “The research team asked KUKA to tender for a bigger cell based on the same technology so that they could work on larger components. A new design was evolved and the new cell was built and installed over a six-month period.”
He added that discussions were now underway with the Nuclear AMRC team on how to upgrade the cell and further expand its capabilities and flexibility.
KUKA Systems UK, based in Halesowen, West Midlands, produces automated production solutions for a wide range of industry sectors including aerospace, automotive and nuclear decommissioning.
Visit the KUKA Systems website for more information.
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