A pair of Kuka KR Cybertech nano arc welding robots running on a linear track weld the seams automatically in the required sequence. The simulation determines exactly when each robot should take over which weld seam to avoid distortion, and ensure that the seams are tight. It also helps to reduce cycle times. Hase reports that it has reduced the risk of failure due to operator errors significantly. In addition, all current programs are backed up, so even if an error occurs, all data can be restored immediately. “We wanted to connect the virtual world optimally with the real world,” says Bernd von der Bank from the welding system specialist, Paul von der Bank, who carried out the project. “It doesn’t matter whether I change something on the system or in the simulation, as the same thing happens in both. The fact that the online and real worlds harmonise so well is unique in the market. “The challenge with electric welding is that the virtual world has no tolerances,” von der Bank adds. “The actual joining technology, on the other hand, does – and they are not exactly small. To ensure that the simulation of welding seams and the welding parameters optimally matched the work of the robot controller and that the ‘post-teaching’ effort was as low as possible, all parties worked together to modify Kuka.Sim according to suit Hase’s needs – the software’s modular architecture makes this possible. “The data is 100% consistent, meaning the virtual controller and the real controller work with the exact same data.” In this way, the digital twin software offers the basis for virtual start-ups. Space savings Hase has been able to cut the welding time per stove from 45 minutes to just 15. The company has since commissioned a second, identical system, helping to keep the programming and control workloads low. The two systems have replaced five older ones, resulting in significant space savings on the production floor. Hase can now manufacture up to 25,000 stoves per year, compared to a previous limit of 15,000. “The two high-end robot systems are the greatest welding innovation we have ever had,” Fischer concludes. “The most difficult thing about automation is finding a way to cover a broad product portfolio at the same time. We successfully solved this challenge, together with Kuka and Paul von der Bank.” Hase’s employees see the automation not as a threat to their jobs, but as a way to secure the viability of their employer. Hase plans to continue combining traditional craftsmanship with cutting-edge automation. It is already working with Kuka on new concepts for automated edging, painting, and the welding of assemblies, with the aim of ensuring the continued production of clean, modern wood-burning stoves. n ROBOTICS AND AUTOMATED MANUFACTURING n Using the digital twin software, Hase’s production managers can react more flexibly to increasing demand
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