When Sandbach based company, Newfield Fabrications Co Ltd, were considering to expand their robot welding capacity for larger assemblies to the yellow goods industry and to such companies like JCB, ERF and Foden, they needed a system that was both flexible and capable of keeping up with future demands. The family owned business led my Managing Director, David Binns had already been an established user of MOTOMAN robots since 1997 and this equipment had provided good returns. The new system should be able to cope with small production runs as this is the nature of this leading fabricator. Main consideration should be given to large fabrications weighing up to 2000 kg with a maximum length of 3 meters and a width of 2.6 m. In addition the robot system should be able to weld all of the joints, which meant high accessibility from the robot. An other consideration was the restricted amount of floor space and the companies desire to occasionally be able to weld fabrications in excess of 4 m in length in a twin station robot cell.
YASKAWA's solution comprises two HSB 5000 single axes head and tail stock work piece
positioners, which were position in an "in-
According to Mr David Binns: "Not only has the system been a major asset in ensuring that Newfield Fabrications Co Ltd were able to cope with increased demands for welded assemblies, but it has also allowed us to address our production costs in an area where it is difficult to employ skilled welders." Mr Binns also recognises the added value of having servo controlled positioners which ensure increased weld quality and at least 10% savings in manufacturing cost. One of the reasons for selection YASKAWA for this project was that all auxiliary equipment such as the gantry system and positioners are standard MOTOMAN products with a high reputation for reliability and excellent integration with the MOTOMAN robot system.
Newfield Fabrications Co Ltd
Welded assemblies for the yellow goods and truck sector
MOTOMAN HP6 robot
MOTOMAN XYZ gantry system
MOTOMAN HSB 5000 positioners
MOTOMAN ComArc joint sensor
MOTOMAN ComArc seam follower
Ability to produce large robot welded assemblies at a competitive cost
Reduced dependence on skilled welders
Maximum flexibility with tight floor space
Reduction manufacturing cost with servo positioners: 10%
YASKAWA UK Ltd