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Comau Spot Welding Machine

Published 24 May 2012 | By COMAU

Comau unveils a cutting‐edge spot welding machine ‐ a compact solution that is set to transform the world of welding.

Productivity, reliability and integrated elements are the base lines of this highly efficient system that is able to meet the challenges of today's global market.

This system integrates a welding gun with the flange connected directly to the robot without the need for any adapter kit. The result is a light and compact product, able to sustain a high payload and, therefore, it is an ideal spot welding system for the automotive industry.

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From the very beginning, through initial analysis and benchmarking, Comau teams worked to optimize all of the system's components. This led to the inception of the new spot welding gun, with a total weight of 40% less than previous models. It features a compact welding gun equipped with an improved transformer, which is rotated 90° to further decrease the dimensions of the body and shift the center of gravity closer to the robot's wrist.

Rendered unnecessary, the pneumatic cylinder for balancing the welding gun has been eliminated and, now, the fieldbus module and the flexion of the gun arms are controlled through the robot's software; this ensures welding quality and accuracy.
The cooling pipes and cables are housed within a protective cover that guarantees maximum safeguard from wear. Its defined layout allows positioning repeatability even after maintenance services and interventions.

This welding gun marks a new standard that can be installed and used with all robots, even as a retro-fit - offering maximum flexibility and modularity in response to production demands.

Along with the welding gun, the latest generation of robots has been developed, following in-depth research related to materials and design. The result is a compact, lightweight robot that has maintained the same functional range of the arm by optimizing the dimensions of each individual component, such as the engines.

One key point, with respect to the spot welding machine's accuracy, is the complete integration of the cables and pipes running to the welding gun inside the robot arm. This solution, which is unique to the field, is the culmination of years of experience and continual development; it has made it possible to offer an eight-year warranty for the robot configuration.

The system has been improved from every perspective - refining the algorithms and the logic of movements, so that it is now free of redundancies.

Together, the robot and welding gun symbolize the hinge of the Comau new spot welding machines, which will open the door to a new paradigm in welding.

Thanks to its reduced weight and dimensions, today it is possible to create new welding cells and islands that are highly dense, in order to increase the number of robots simultaneously in action. Greater density translates to greater energy efficiency, reduced operating costs and lower cycle times.

This welding machine can also be installed on the ceiling, opening up more functional space. The free space on the ground guarantees greater control of the production line and grants operators easier access for maintenance and re-tooling jobs.
Developed this way, the cell can be transported and installed whole throughout the world, achieving optimal modularity and standardization of operational processes on a global level.

The spot welding machine was developed in Italy at Comau in Grugliasco, just outside of Turin. Developing highly efficient solutions that have a positive effect on operating costs and reduced environmental impact means developing integrated systems that are characterized by increased component reliability.

From this perspective, it is clear how this spot welding machine is a great representation of Comau technological vision - to introduce a convergent evolution to the world of industrial technology.