Caring for Care
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Caring for Care
With a clever welding production line
No room for failure: lives are at stake when Haelvoet’s solutions are needed. All over Europe hospitals and elderly care homes rely on the Belgium company as the quality leader for medical beds. Matching the high standards, Panasonic’s G4 TAWERS (The Arc Welding Robot System) welding robot system was selected for the production.
Challenge
The newest production line is supposed to produce four alternatives of the same product with ideally no ramp-up time, perfect welding results and zero tolerance for mistakes.
Solution
Panasonic with the support of its partner SYN-TIG developed a flexible welding production line for a medical bedframe with variations - where all parts of all variations are automatically detected. Awaiting a human confirmation the correct welding program starts automatically.
"We will be able to control the jigs with the PLC. The solution helps us to manage welding objects with different dimesons in the same robot without further teaching or ramp-up. Based on the automatically recognized parts the welding systems automatically starts the correct program."
Managing Engineer
Grovinvest
The Belgium company Haelvoet has an admirable and respectable mission. They want nothing less than to “develop and create furniture and surroundings that enable people to live as independently as possible”. The production of the company is hosted in the small town Jibou in the North of Romania. About 150 employees manufacture medical beds and medical relax chairs. The customers are located all over Europe, but they have one thing in common: a zero tolerance for poor quality and a high demand for premium quality.
An expectation Grovinvest always met - always with the help of Panasonic’s arc welding robots. The Japanese welding specialist installed its first system in Jibou in 2009, the second in 2014. The robot cells have been running ever since with no to low maintenance in a two-, sometimes three-shift production. In 2024, Panasonic together with its partner SYN-TIG, delivered an upgrade – to support a more and more flexible and first automated production.
More than 15 Years of reliable Performance
The welding robot of the newest generation is working closely with two older Panasonic robot cells, a G2 and a G3 system. “The G4 serves as an improvement, but the older generations are still reliable and working well”, explains Bogdan Pienaru, the managing engineer from Grovinvest. When asked, he pointed out that the contact tips consumable have a longer lifetime and less needed to be replaced.
Still, he points out the advantages he sees in the G4: “Loading a new program is easier, the teach pendant with touch screen function is full intuitive to use, and the gap between input and movement is much faster. The whole system is obviously much faster.” Last but not least has the welding quality -already coming from a high standard and always a plus on Panasonic’s side as Bogdan mentioned- been further improved.
The G4 is part of a new production line. As Mr. Pienaru says: "Our aim was to develop a flexible jig system that can dynamically fix parts of different dimensions and automatically recognize them, so that the right program is called up directly." Grovinvest heard of the new technology, the advantages of the new controller, especially with respect to the automated parts recognition.
Currently the production line is still testing samples, but the go live is planned for November. “Key element are the pneumatic clamps with the parts detection”, stresses László Kovács, managing director at SYN-TIG, a long-term development and installation partner from Panasonic. Once an operator connects the plug, the robot will recognize the part and automatically start the correct program. With the aim to manufacture several variations, 6 widths and 2 lengths, of the same product and each product consisting of more than 30 parts, the automated recognition is important – but the human factor needs also to be factored in. “During that process an image of the part shows at the HMI monitor of the PLC, not only the product but also the correct closing of the clams is recognized”, so Bogdan Pienaru from Grovinvest.
The engineer from in Brasov studied Aerospace Technology and started as first employee of Grovinvest, 18 years ago in the company. He speaks in high terms of Panasonic and SYN-TIG: “The solution and the service provided by Panasonic and its partner was excellent. For such a project we needed a partner who is open for our ideas, reachable and comes immediately to discuss open questions or solve any problems.”
Alexander Thomas, Senior Account Manager Panasonic Connect, summarizes the project: “Be the best among the good guys – with the help of robot technology from Panasonic and the project development expertise of our resourceful and experienced partner SYN-TIG.”
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