Robot-assisted plasma cutting systems with outstanding flexibility

TASK

Tube and profile processing in a batch size of one

Batch size one and robot-supported automation: This is a challenging combination. The challenge becomes even greater when plasma cutting tools must be positioned with high precision for each batch in steel tube and profile processing.

As steel processing becomes increasingly complex and regulations become stricter, it is nearly impossible to perform the necessary work manually. For this reason, Dutch machine manufacturer HGG Profiling Equipment BV has set the goal of providing the world of steel processing with precise, versatile, and highly productive machines.

SOLUTION

High-precision robots, perfectly synchronized

HGG’s machines are capable of producing individual, one-off steel parts at high speed and with high precision. There are several types of machines for this task, from the very compact RoboRail to the top-of-the-range model, the RPC 1200. Both are designed for processing 3D parts such as beams, tubes, and profiles with a wall thickness of up to 120 mm. Both use Stäubli six-axis robots from the TX2 series.

The demands placed on the robots are high. They must be highly precise in each axis and each individual cutting process, and particularly with batch sizes of one, this requires perfect synchronization of multiple axes. To ensure this synchronization, the HGG designers rely on Stäubli’s uniVAL drive interface: a plug-and-play solution for communication between Stäubli robots with standard motion controllers.

While the compact RoboRail, mainly designed for cutting pipes and smaller profiles, uses a TX2-60L with a plasma cutting head, the top model in the plasma cutting range, the RPC, is equipped with a larger TX2-90. It is mainly used for cutting large beams and square tubes for structural steel construction.

CUSTOMER USAGE

Reliable even under adverse conditions

In addition to the precision and coordination of all axes, there is another important characteristic that the robots on HGG's machines must have: perfect sealing of all moving axes and joints against abrasive fine dust. Here, too, Stäubli robots prove their worth, thanks to their unique, fully encapsulated design.

In addition, the combination of Stäubli robots with external axes offers clear advantages from HGG's point of view. The very high positioning accuracy of the robots and the additional reach provided by the external axes ensure a very precise and highly flexible system.