Nine-axis cantilever workstation – Technical solution

by Shaanxi Jingtai Cooperation Laser technology Co.,Ltd

This solution is applicable to the intelligent welding of typical workpieces in the industry.
Unified description of weld analysis:
(1) Red markings indicate weldability, and yellow markings indicate non – weldability.

(2) Welds at typical parts are marked. Welds of the same type but at different parts may have their markings omitted. Other unmarked parts are not to be welded.

(3) The height \(H\) and spacing \(W\) of the part plates must meet the requirements in the chart. If they exceed the range, the standard welding torch cannot be used for welding.

4) The included angle (tilt angle) α of the part plate should not be less than 70 degrees. If it exceeds this angle, the welding quality when the welding torch descends will be affected.

Vertical plate height (H)	Plate spacing (W)	Specification
50	80	The visual recognition is on the exterior
100	120	The visual recognition is on the exterior
200	280	Includes visual recognition space
300	340	Includes visual recognition space
400	420	Includes visual recognition space
550	500	Includes visual recognition space

Three-dimensional schematic diagram of the workstation

Planar schematic diagram of the workstation

Side schematic diagram of the workstation

The column lowers to the minimum height:5200mm.
The column raises to the maximum height:6700mm.

Technical parameters

The workstation covers an area of approximately		26000mm × 8000mm
It is suitable for the maximum workpiece size of (Width × Height, and the length is adaptable to the length of the X-axis track)		3500mm × 1500mm
Name	Nine-axis cantilever walking system	Installation environment	Temperature	-10 ~ 45 °C
Model	JTC-12X-2.5Y-1.5Z		Humidity	20–80%
Load	500 kg		Vibration	Below 4.9 m/s²
Positioning accuracy	±0.5 mm in static state ±0.8 mm in motion state		Other	No flammable or corrosive gases and liquids. Water and oil are not allowed. Keep away from high-intensity interference sources.
Number of additional axes	3
Length of X-direction track	12 m 6 m		Maximum walking speed	18 M/min
Effective length in Y direction	2.5 m 2 m		Maximum walking speed	18 M/min
Effective length in Z direction	1.5 m 1.5 m		Maximum walking speed	12 M/min

Equipment Name			Nine-axis Cantilever Intelligent Workstation			Number of Workstations	2
Serial Number	Sub-item	Description	Name	Unit	Quantity	Brand/Manufacturer	Remarks
1	Software System	Operating System	Intelligent Operating System	SET	2	OS	English Version
		Operating System	Vision System	SET	2	OS	English Version
		Hardware Operating System	Industrial Computer/Control Console	SET	2	OS
2	Hardware Configuration	Vision Body	3 in 1 Camera	SET	2	RVC-sensor	RVC-M2600 (with stand)
		Vision Body	Large field Camera	SET	2	RVC-sensor	RVC-G52000 (with stand)
		Robot System	Welding Robot	SET	2	KUKA	KR 16 R2010-2
		Welding Equipment	Water-cooled Welding Torch	SET	2	TRM	Water-cooled welding torch TRM605WHD
		Welding Equipment	Welding Machine	SET	2	Aotai	NBC-500RP Plus
		Traveling System	Traveling Additional Axis	SET	2	Hongyi	JTC-12X-2.5Y-1.5Z
			Servo Motor	SET	2	Kaibang	X-axis (5.5kw) / X-axis (3.14kw)
				SET	2		Y-axis (2kw)
				SET	2		Z-axis (3.14kw)
3	Auxiliary Configuration	Welding Auxiliary	Welding Gun Cleaning Station	SET	2	TRM	SC220ASE

Process Description:
1. Positioning and spot welding of workpieces is manually performed at Workstation 1. Then, the robot moves to Workstation 1 and conducts overall identification and reverse modeling of the workpiece through the global camera (multiple workpieces can be identified simultaneously).

2. After the system obtains the data, it generates a precise positioning program to drive the robot’s end – effector vision to conduct precise scanning in a node – based mode.

3. Once the scanning is completed, the system generates a welding program, and the robot executes the welding.

4. While the robot is working as described above, manual assembly and spot – welding are carried out at Workstation 2.

After the robot finishes welding the workpiece at Workstation 1, it moves to Workstation 2 to perform the above – mentioned welding tasks.

5. Workers transfer the welded finished products at Workstation 1 to the subsequent workstations.

Operating System OS

The system is completely independently developed byus. Its main function is to deeply integrate the welding process. It accurately locates the component welds through the vision system. Based on the obtained weld coordinate information, it automatically generates welding programs by integrating the welding expert database.

The software is deployed on the PC system. The PC system can be placed anywhere, and remote control of the equipment for welding can be achieved through the TCP/IP protocol.

Welding Robot - KUKA

■ Rigid design endows the robot with excellent positioning ability during arc welding, and its repeat positioning accuracy can reach ±0.04 mm.

■ Based on the latest KR C5 S control cabinet ecosystem, it includes the KUKA arc welding software package and external axis product portfolio, covering process packages such as arc tracking, starting point positioning, multi – layer and multi – pass welding, laser positioning, laser tracking, and robot collaborative operation.

■ Unaffected by low temperatures, it can operate normally in the temperature range of 0 – 45°C.

■ It can be compatible with mainstream welding machines on the market to ensure communication.

■ The increase in welding speed effectively shortens the welding cycle and realizes high production efficiency.

Technical Data Product KR 16 R2010-2
Specification	Value
Number of Axes	6
Controllable Axes	6
Work Envelope Volume	32.5 m³
Pose Repeatability (ISO 9283)	±0.04 mm
Weight	260 kg
Rated Payload	16 kg
Maximum Payload	19.2 kg
Maximum Reach	2013 mm
Protection Rating (IEC 60529)	IP65
Robot Wrist Protection Rating (IEC 60529)	IP65
Noise Level	<65 dB(A)
Installation Position	Floor; Ceiling; Wall; At any angle
Footprint	430.5mm x 370 mm
Mounting Face Drilling Pattern	S310
Permitted Tilt Angle	±180°
Standard Colors	Base: Black (RAL 9005); Moving Parts: KUKA Industrial Orange (RAL 2009)
Controller	KR C5 S6/S7; KR C4
Transformer Designation	KR C4: KR16R2010_2 C4; KR C5: KR16R2010_2 C4

Welding Robot – KUKA
Robot Motion Range: KR 16 R2010-2

Welding Machine - Aotai

■Functions: It has functions such as constant – voltage gas – shielded welding, manual arc welding, and large penetration. It is suitable for welding carbon steel, stainless steel, and their flux – cored wires.

■Digital Features: It is equipped with built – in digital devices like card – swiping, IOT group – control function, 485 dedicated – machine interface function, and gas flow meter. The password – based single – machine limiting function is standard – equipped, which is convenient for the management of welders not in group – control scenarios.

■New Main – circuit Design: With a new main – circuit design, the working frequency of the main circuit is increased to three times that of the basic model, and the output power is increased by 15%. This makes the root pass welding and vertical welding with small current more stable. For large – current long – cable welding, it can provide more sufficient and sustainable output power

Serial Number	Category	NBC-500RP Plus
1	Rated Input Voltage/Frequency	Three-phase 380V ± 10%, 50Hz
2	Rated Input Capacity (KVA)	24
3	Rated Input Current (A)	38
4	Rated Output Voltage (V)	39
5	Rated Duty Cycle (%)	100
6	Output No-load Voltage (V)	106
7	Weight (Kg)	55
8	Output Range (A/V)	60A/17V～500A/39V
9	Wire Diameter (mm)	0.8/1.0/1.2/1.6
10	Gas Flow Rate (L/min)	15～20
11	Enclosure Protection Class	IP23
12	EMC Emission Class	A
13	Insulation Class	H
14	Overall Dimensions L×W×H (mm)	660×320×560

Welding Torch - Therma TRM605WHD

The welding torch is a Therma robotic liquid – cooled welding torch, mainly composed of a liquid – cooled gun neck and cables. Innovatively, the welding torch adopts a two – way shielding gas design. This design results in an excellent gas shielding effect during welding. Meanwhile, the consumption of shielding gas is significantly reduced. The cooling effect of the welding torch is enhanced, which extends the service life of the contact tip.

TCP Data
a	A (mm)	B (mm)		Gun Neck Angle	Gun Neck Model
22°	44.3	392.63		22°	550WTE51-22L341H023
Technical Parameters
Parameter Name	Parameter Value		Other Instructions
Cooling Method	Liquid-cooled		The gun neck is replaceable. The welding torch has a built-in water-stop function for easy replacement and maintenance.
Rating	550A CO₂ / 500A mixed gas (80%Ar + 20%CO₂)		Anti-collision function is standard
Duty Cycle	100%		—
Wire Diameter	φ0.8 – 1.6mm		—
Gun Neck Angle	22°, 36°, 45°		Gun necks with multiple angles and lengths are available

Vision - Ruban Tri - in - one Camera

The RVC – M2600 3D camera utilizes self – developed structured – light core components and an innovative ambient – light – resistant algorithm, enabling it to image facing welding arcs and the sun. By applying a binocular dynamic compensation algorithm, it can obtain high – quality point clouds even under near – specular reflection conditions. It features strong resistance to ambient light interference, dual – mode shooting of line – scan and area – array, and is stable and easy to use. It is suitable for scenarios such as metal welding, outdoor inspection, polishing, sheet – metal spraying, loading and unloading.

Product Reference Data
Basic Data	Camera Dimensions (mm)	148 × 73.5 × 73.5
	Camera Weight (kg)	0.95
	Baseline Length (mm)	93
	Camera Resolution	1440 × 1080 (1.6M), binocular, grayscale
	Light Source	Laser
	Data Interface	Gigabit Ethernet
	Operating Voltage / Current	DC 24V / 2A
	SDK – supported Systems	Linux / Windows
	SDK – supported Languages	C / C++ / C# / Python
Performance Parameters	Working Distance (mm)	400 – 1000
	Depth of Field (mm)	600
	Near-field of View (mm)	350 × 220 @ 400
	Field of View at Optimal Working Distance (mm)	600 × 450 @ 700
	Far-field of View (mm)	860 × 650 @ 1000
	Z – single-point Repeatability Accuracy (mm)	0.27 @ 1000
	Z – area Repeatability Accuracy (mm)	0.05 @ 1000
	XYZ Spatial Measurement Error	Full FOV < 0.2% Center FOV < 0.1%
	Point Spacing (mm)	0.25 @ 400 0.7 @ 1000
	Shooting Time (s/frame)	0.98 – 2.26
Stability	Enclosure Protection	IP65 protection level
	Ambient Light Resistance	Line-scan mode > 400,000 Lux
	Operating Temperature	-20 – 50 ℃

Vision - Ruban Global Camera

The RVC – G52000 super – large field – of – view 3D camera features a super – large field of view of 2.9×2.5×3m, a large depth of field of 1.8 meters, sub – millimeter – level accuracy, good point – cloud stability, IP65 – level protection, and excellent ambient – light – resistance performance. It can quickly measure various objects such as closely stacked and disorderly placed cartons, sacks, steel – plate workpieces, etc., and output complete and accurate high – quality 3D point – cloud data. It is widely applicable to typical palletizing and depalletizing, as well as handling scenarios in logistics, express delivery, heavy – industry machinery, etc.

Product Reference Data
Model	RVC-G52000
Shortest Shooting Time (seconds/frame)	1.7
Resolution	2448×2048 (5MP), binocular, grayscale
Working Distance Range (mm)	1200-3000
Near Field of View (FOV) (mm)	1050×1000@1200
Far Field of View (FOV) (mm)	2900×2500@3000
Resolution in XY Direction (mm)	0.5-1.2
Z-axis Single-point Repeatability Accuracy (mm)	0.39
Z-axis Area Repeatability Accuracy (mm)	0.01
Light Source	Laser
Communication Interface	Gigabit Ethernet
Camera Weight (kg)	2.9
Camera Dimensions (mm)	692×93.5×81
Operating Voltage / Current	DC24V/3.75A
Protection Level	IP65
Operating Temperature (℃)	0~45
Operating Humidity (%RH)	20 – 80 (no condensation)
Standard Accessories	Power adapter, power cord, data cable
Support for Third-party Development	Yes
Supported Programming Languages	C/C++/C#/Python
Supported Development Platforms	Linux/Windows
Compatible Third-party Software Libraries	Halcon/OpenCV/Open3D/PCL/VisionPro

Welding Torch Cleaning Station - TERMA

This cleaning station is designed to remove spatters that adhere and clog the gas shield sleeve of the welding torch during the automatic welding operation of the welding robot. By doing so, it ensures the long – term unobstructed flow of gas, effectively blocks air from entering the welding area, and improves the quality of the weld seam. It also cleans the dust generated by welding fumes on the contact tip and the gas outlet holes on the connecting pipe. Additionally, it sprays torch – cleaning agent onto the gas shield sleeve to reduce the tenacious adhesion of welding slag to the nozzle and the contact tip, thereby increasing their durability.

This significantly reduces the workload of operators. It prevents the situation where untimely manual cleaning affects the welding quality. Moreover, it avoids the wear of the insulating cylinder threads between the gas shield sleeve and the body connecting pipe caused by repeated disassembly and assembly during manual cleaning, thus extending the service life, reducing costs.

It also prevents the gas shield sleeve from being installed obliquely due to thread wear, which could lead to gas deflection and ultimately cause the failure of gas protection.

Serial Number	Parameter Name	Parameter Description
1	Pneumatic Welding Torch Cleaner SC220ASE	Matches with industrial welding torches, removes spatters and trims excess welding wire.
2	Anti-spatter Liquid SC221A-PS	Contains 250 ml of anti-spatter liquid.
3	Wire-cutting Blade SC200A-JS	Cuts off the ball formed at the front end of the welding wire.
4	Industrial Reamer ANC1511-40	Removes spatters. It is applicable for a spray nozzle with an inner diameter of 16 mm and a contact tip with an outer diameter of 10 mm.
5	Input Air Pressure	The air pressure should reach over 0.6 Mpa.
6	Air Consumption	Approximately 10 L/S.
7	Pneumatic Motor	Rotates at about 650 rpm, with a maximum torque of 8 N·m.
8	Control Current/Voltage	24VDC / Imax = 0.15A
9	Wire-cutting Time	Approximately 0.5 seconds.
10	Wire-cutting Capacity	For solid-core welding wire, the maximum diameter is 1.6 mm; for flux-cored welding wire, the maximum diameter is 3.2 mm.

45-foot High Cube Container Dimensions (Open Top)

Container Type	Internal Dimensions (L × W × H)	External Dimensions (L × W × H)	Volume	Tare Weight
45ft High Cube	13556 mm × 2352 mm × 2698 mm	13716 mm × 2438 mm × 2896 mm	86 m³	4800–5000 kg

Structural form: H-beam, plate-rib unit, partition unit

Packing Simulation Instructions

Structural form: H-beam, plate-rib unit, partition unit