PSI - Issue 66

S. Skrobacz et al. / Procedia Structural Integrity 66 (2024) 11–25 S. Skrobacz¹², P. Krysi ń ski¹, S. Ma ł ys¹², T. Ł agoda², / Structural Integrity Procedia 00 (2025) 000–000

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Figure 1. 3D Visualization of the Welding Cell.

The stations are equipped with an IGM RTE459 robot arm that operates on seven rotational axes. The arm is specifically designed for arc welding to facilitate access to welds located in difficult-to-reach areas of the structure. Its media conduits are routed internally through the main axis, then through the auxiliary axis up to the torch. All air lines, welding cables, control lines, and even the welding wire are routed through the robot base. No hoses or lines run outside the robot base, eliminating the possibility of obstructing the robot's moving parts or other objects in the cell. This setup facilitates the start of the weld and helps maintain the cleanliness of the workstation, thereby improving weld quality. The robot arm is mounted on an IGM RR-MK rotary system. The rotary table is designed with a stable structure made of formed steel and is driven by an AC servo motor, rotating either to the right or left, and is automatically positioned in work positions offset by 180° presented in Figure 2. The vertical column is designed using a stably welded structure made of formed steel with machined front, axial surfaces, and centering pins for mounting on the rotary module Figure 4. This mechanism is used to manipulate the workpiece in a horizontal position. The drive is axially controlled and powered by an AC servo motor with a special gearbox and an integrated digital position sensor. The rotary fixture serves as an additional external axis of the robot's rotation presented in Figure 3. The movement of the workpiece is fully integrated into the robot's control system, allowing for synchronized movement of the workpiece during the welding sequence.

Figure 2. Visualization of the RTE 459 Robot Arm's Reach.