Success Stories
Advanced Robotic Welding System for Zabag’s Custom Sliding Gates
Company Background
Zabag Security Engineering GmbH, based in Grünhainichen, Germany, is a leading expert in the design and manufacturing of security systems, particularly for large-scale gates and access control solutions. When Zabag was tasked with creating a robust and efficient system for welding large, free-standing sliding gates, the company turned to OTC DAIHEN EUROPE for a solution. These gates, with lengths of up to 18 meters and heights up to 2.4 meters, required a precise and flexible welding system capable of handling both aluminum and steel materials. The challenge was to develop an automated system that could consistently deliver high-quality results, even with the variability of material properties and the large scale of the gates.
Robotic Welding Solution – A Custom Automation System
To meet Zabag's unique needs, OTC DAIHEN EUROPE designed and implemented a comprehensive robotic system with a remarkable 40-meter length. The system, which includes three robotic arms, is dedicated to the precise and automated welding of these large gates. After an extensive testing and optimization phase, the system was successfully delivered, incorporating substantial technical expertise to ensure flawless operation. The automation solution was tailored to handle the intricate welding tasks and variable material types, streamlining the production process while maintaining the highest quality standards.
Technical Features of the Robotic Welding System:
- Robotic Technology: The system utilizes three OTC robots: one 200kg handling robot for positioning the components and two long-arm welding robots for the welding process.
- Automation Process: The system's design allows for the automated selection of gate dimensions (height, width) and material type (aluminum or steel) directly via the machine's control panel, ensuring optimal welding conditions for each specific part.
- Continuous Material Handling: After the profiles (semi-finished components) are loaded into the system and the corresponding welding program is selected, the handling robot retrieves the components from the magazines, feeds them into the process, and positions them for welding.
- Intelligent Sensors for Process Control: The system is equipped with advanced sensors that continuously monitor and adjust the process to compensate for material tolerances, ensuring smooth operation and high-quality results throughout the production cycle.
Benefits of the Fully Automated Welding System:
- Precision and Consistency: The high degree of automation ensures that the welding process is carried out under consistent conditions, resulting in uniform quality for every gate produced, regardless of material or size.
- Efficiency and Flexibility: The system's automated material handling and welding capabilities enable the production of large, custom gates in varying dimensions and materials, significantly improving manufacturing efficiency and reducing production time.
- High-Quality Welding: With the integration of the long-arm welding robots and continuous monitoring by intelligent sensors, the system ensures precise welds, even for large and complex gate structures.
- Intelligent Control: The specially developed machine control system manages the entire process, allowing the operator to select and adjust welding parameters easily, ensuring the production of gates that meet the highest safety and quality standards.
Conclusion
The robotic welding system developed by OTC DAIHEN EUROPE for Zabag Security Engineering is a prime example of how advanced automation can optimize manufacturing processes, even for large-scale, complex production requirements. By combining OTC’s expertise in robotics and welding technology, the system provides Zabag with an efficient and highly reliable solution for producing large sliding gates. This installation underscores OTC’s ability to implement highly customized, automated systems that meet the unique demands of its clients, establishing the company as a leading provider of advanced automation solutions in the welding industry.
