Project Description

Higher profit through the use of the UR5

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How do you increase your profits? - The result

The automation solution from Universal Robots has increased profits at Ferdinand Wagner Profile. The automation solution must be able to deliver consistent, high-quality welding. The chosen solution is perfect for this. It sorts, welds and solders all parts with the utmost care and precision. This enables Ferdinand Wagner Profile to deliver high-quality products.

The challenge in the company

With a production of 500,000 to 600,000 hand-soldered and hand-welded parts per year, the company was reaching its limits. Constantly changing conditions made production lines ineffective and the costs for end products were difficult to calculate.

A sophisticated solution therefore had to be developed. It made sense to divide the process into several stages, each of which prioritized quality. In the first part, unprocessed parts were to be prepared and secured without intervention. They were then to be taken to the welding station, where they were to be positioned correctly.

Another important factor was the seasonal nature of the work. Depending on the season, the products change and production also has to be adapted. The solution must therefore be flexible and easy to program.

  • Difficult cost calculation
  • Sophisticated structure
  • Seasonal order situation

"This helps us to improve our productivity across the board. And has enabled us to achieve our cost stability targets."

Bernhard Eckert , Ferdinand Wagner Profiles

The Universal Robots solution

Ferdinand Wagner relies on two UR5 robots. They work closely together and with the other machines. One of the robots takes care of the initial processes. It selects the parts to be welded, inserts them into an automatic spot welder and places them in a liquid.

In the second process, the second collaborating robot transports the part to a high-frequency soldering station for assembly. After this work, the robot holds the parts in a camera system for automatic inspection.

As Ferdinand Wagner works with sensitive parts and the surfaces must not be damaged, the cobots and grippers are very finely adjusted. This avoids the high costs associated with damaged parts becoming unusable.

Both robots are designed to process 160 parts together. Processing takes place in two-shift intervals, followed by a free shift. Even after the end of the working day, the cobots continue to work in an unnamed shift until the material has been used up.

Employees did not have to be released from their duties. They can now devote themselves to smaller series and thus have significantly more variety.

collaborative robot cobot ferdinand wagner welding

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