& MWR-350TM MWR-100TM. Heavy Duty IntellIgent MobIle WelDIng & gouging/cutting CaRteSIan RobotS. servorobot.com M obi le WelDIng RobotS

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1 COLOR VIDEO CAMERA LASER LINE SCANNER MWR-100TM & MWR-350TM Heavy Duty IntellIgent MobIle WelDIng & gouging/cutting CaRteSIan RobotS M obi le WelDIng RobotS

MWR-100TM Heavy Duty IntellIgent MobIle WelDIng &

configuration TEACH PENDANT MWR TM CONTROLLER WELDING POWER

FEEDER MWR TM ROBOT IDLER CARRIAGE overview SERVO-ROBOT is proud

vision assisted mobile fully programmable welding robots.

and joint type and they are also capable of doing automated

The MWR-350 TM model is designed to weld in all positions.

weldments such as ship stiffeners and mining equipment modules,

systems simultaneously thus reducing the cost of operation.

2 MWR-100TM Heavy Duty IntellIgent MobIle WelDIng & gouging/cutting CaRteSIan RobotS & MWR-350TM MWR TM system configuration TEACH PENDANT MWR TM CONTROLLER WELDING POWER SOURCE LASER-CAMERA AND WELDING TORCH REMOTE MONITORING WIRE FEEDER MWR TM ROBOT IDLER CARRIAGE overview SERVO-ROBOT is proud to intro duce MWR-100 TM and MWR-350 TM, two innovative new vision assisted mobile fully programmable welding robots. These three axes robots are capable of welding on any material and joint type and they are also capable of doing automated plasma beveling and cutting. The MWR-350 TM model is designed to weld in all positions. The portability of the system allows it to be brought onto large weldments such as ship stiffeners and mining equipment modules, thus reducing the need to move the part within the factory which is expensive and time consuming. The simplicity of the system allows the operator to run several systems simultaneously thus reducing the cost of operation. The integrated laser vision seam tracking system has an embedded color video camera which allows remote teaching and process monitoring thus removing the operator from the hazardous welding area.

3 Color 3D/2D scan of weld COLOR VIDEO CAMERA LASER LINE SCANNER POWER-SCANTM COMPaCT WELD BEaD INSPECTION SYSTEM POWER-SCANTM ROBOTIC WELDING INSPECTION SYSTEM I N S P E C T I O N

POWER-SCAN TM COMPaCT WELD BEaD INSPECTION SYSTEM POWER-SCAN TM inspection

Monitoring software package BAD GOOD SYSTEM DESCRIPTION The POWER-SCAN TM system

industrial control unit (POWER-BOX TM ) and a software package (WELDSURE TM ) to

features and BENEfITS Fully integrated system with laser-camera, control unit

Immune to the Arc Welding processes (spatter, heat, etc.).

fume. High-speed digital laser-camera allows for scanning speed up to 6

Informs the robot or PLC when a defect is detected.

4 POWER-SCAN TM COMPaCT WELD BEaD INSPECTION SYSTEM POWER-SCAN TM inspection SySTEM POWER-CAM TM laser-camera mounted on robot POWER-BOX TM control unit Monitoring software package BAD GOOD SYSTEM DESCRIPTION The POWER-SCAN TM system is composed of a 3D laser vision camera head (POWER-CAM TM family), an industrial control unit (POWER-BOX TM ) and a software package (WELDSURE TM ) to perform the inspection of the weld bead. features and BENEfITS Fully integrated system with laser-camera, control unit and software. Very compact control unit with flexible communication interface. Immune to the Arc Welding processes (spatter, heat, etc.). Not affected by ambient lighting conditions. Can inspect welds of any materials. Very rugged laser-camera frame. Pressurized air flow nozzle designed to protect disposable lens against dust and fume. High-speed digital laser-camera allows for scanning speed up to 6 meters/minute (235 inches/minute). Informs the robot or PLC when a defect is detected. Displays the part inspection results on a user-friendly 3D graphical interface. Saves all the inspection data available in the on-board database. Checks joint fit-up. Measures weld shape/geometry. Detects weld defects. Allows for 100% control of the parts produced. Eliminates manual inspection.

EaSY INTEGRaTION Inspection control: Start/Stop Task Selection

CONTROLLER Inspection results: GO/NO GO Defects/types & locations

to make sure the weld Verify that the profiles obtained are Select

acceptance/ rejection boundaries 3.0 < leg size < 4.5 Throat > 2.

5 EaSY INTEGRaTION Inspection control: Start/Stop Task Selection CUSTOMER PLC Interfaces: DIGITAL I/O ETHERNET TCP/IP MODBUS TCP ROBOT CONTROLLER Inspection results: GO/NO GO Defects/types & locations POWER-BOX TM CONTROL UNIT EaSY CONfIGuRaTION Align the laser-camera to make sure the weld Verify that the profiles obtained are Select the inspection template or joint is in its good in WeldCom TM s corresponding to the field of view. user-friendly part configuration graphical interface Step 1 Step 2 Step 3 Step 4 Fillet weld Groove weld... Select which criteria needs to be monitored and set the acceptance/ rejection boundaries 3.0 < leg size < 4.5 Throat > 2.5 Undercut < 0.3 mm user-friendly MONITORING INTERfaCE NetSight TM s 3D View screen showing a defect NetSight TM s detailed screen showing measurements POWER-SCa N TM

LaSER-CaMERa TEChNICaL SPECIfICaTIONS ARC WELDS INSpECtION power-cam power-cam/hr power-cam tm power-cam/hr tm Stand-off to camera 70 mm 92 mm Close plane (Field of view) 27 mm 12.

6 LaSER-CaMERa TEChNICaL SPECIfICaTIONS ARC WELDS INSpECtION power-cam power-cam/hr power-cam tm power-cam/hr tm Stand-off to camera 70 mm 92 mm Close plane (Field of view) 27 mm 12.5 mm Far plane (Field of view) 76 mm 15 mm Depth of field 140 mm 16 mm Average depth resolution 0.09 mm mm Average lateral resolution 0.05 mm mm Weight 475 g 500 g Dimensions (mm) [H x W x D] 94 x 33 x x 33 x 58 Best suited for Medium to Heavy Plate Sheet Metal Integrated color video camera for monitoring 3 3 Operating temperature range: 5 to 40 C (41 F to 104 F) Laser : Class IIIb JOINT INSPECTION Features Joint type t-joint Butt Joint (Square, V and Bevel Groove) Beta Angle 30 to to 200 Root Opening 0 to 6 mm 0 to 10 mm Mismatch/Hi-Lo N.A. 0 to 6 mm COMPLETE PROCESS quality assesment ThROuGh high accuracy 3D LaSER PROfILING TEChNOLOGY Groove Angle N.A. 30 to 90 Bevel Angle (l,r) N.A. 15 to 45 N.A. - Not Applicable WELD INSPECTION Weld type Fillet weld Groove weld Features Leg and Size (l,r) 2 to 50 mm N.A. Theoretical Throat 2 to 35 mm N.A. Convexity 0 to 20 mm 0 to 20 mm Reinforcement N.A. 0 to 20 mm Undercut (l,r) 0 to 3 mm 0 to 3 mm Toe Angle (l,r) 90 to to 180 Mismatch/Hi-Lo N.A. 0 to 6 mm Beta Angle 30 to to 200 Face Width N.A. 2 to 55 mm Porosity, Cracks and Spatter 0.5 to 5 mm 0.5 to 5 mm VISIBLE LASER RADIATION AVOID DIRECT EXPOSURE TO BEAM AlGaInP 130 mw Max Class IIIb - CDRH Class 3B - IEC N.A. - Not Applicable SERVO-ROBOt INC HOCQUART, SAINT-BRUNO, QUEBEC, CANADA J3V 6E1 TEL: FAX: sales@ SERVO-ROBOT reserves the right to change product specifications without notice SERVO-ROBOT Inc., All Rights Reserved. Printed in China. TPOWSC1208E011

features and benefits Dramatic quality and productivity improvements are easily achieved compared to manual and

Remote process monitoring removes operator from welding zone.

Easily integrates to any welding system. Automated teaching reduces setup time and increases flexibility.

easy to use - In less than one hour, you will be welding like a pro.

MInIng 4 Lightweight cartesian robot with ergonomic teach pendant provides high level of safety for the operator.

4 Rugged robot made to survive in toughest factory environment.

7 features and benefits Dramatic quality and productivity improvements are easily achieved compared to manual and mechanized welding. Mobile so automation can be brought to the workpiece. Remote process monitoring removes operator from welding zone. Precise seam tracking for consistent penetration and accurate bead placement. Easily integrates to any welding system. Automated teaching reduces setup time and increases flexibility. Multilayer welding. Welding parameters can be optimized via the teach pendant. The actual tracking profile is visually shown on the color touch screen of the teach pendant. typical applications SHIPbuIlDIng QualIty and PRoDuCtIvIty IMPRoveMentS are easily achieved RaIlRoaD 4 Extremely easy to use - In less than one hour, you will be welding like a pro. 4 Robot is sensor ready - Seam tracking, video monitoring and GPS functions can easily be added. MInIng 4 Lightweight cartesian robot with ergonomic teach pendant provides high level of safety for the operator. 4 Perfect for welding in all positions on any type of joint. 4 Rugged robot made to survive in toughest factory environment. ConStRuCtIon 4 Capable of also doing automated plasma cutting and beveling which improves joint preparation quality. 4 Modularity allows robot to be used in conjunction with hard automation arc welding machines to improve their flexibility. Vertical mobile welding robot PoWeR generation WItH vision tm SySteM Joint Tracking. Adaptive control of welding parameters based on joint geometry. Vision assisted robot teaching for easy path programming. M wr tm

8 MobIle WelDIng RobotS technical SPeCIfICatIonS Mwr-100 Mwr-350 Weight Dimensions (excluding accessories) Lateral Axis (Y) Stroke Vertical Axis (Z) Stroke Rail Compatibility HArDwAre 27 kg 504 mm Width x 380 mm Height x 351 mm Length 150 mm 150 mm Gullco type rails Load Carrying Capability 45 kg / Flat and horizontal only 160 kg / All positions Maximum Load on the Y and Z Axes Maximum Travel Speed Maximum Cable Length Torch Holder Optional Idler Carriage for Wire Feeder and Wire Spool 25 kg 2.5 m/minute 30 m Manually adjustable lead/lag and work angles Lead/lag angle: +70 /-15 degrees Work angle: +/- 15 degrees Yes. Can be pulled or pushed Dimensions Weight Weaving Welding Power Source Control Robot Programming Method Path Control Programs Power Failure Protection Pause/Restart Support Connection Display Safety Backup Monitoring Cable control unit characteristics 500 mm Width x 500 mm Height x 200 mm Depth 27kg Triangular weave Programmable width and frequency 3 programmable dwell times: left, center, right Y axis only or perpendicular to the torch axis Ethernet link for ArcLink interface; Analog and Digital I/O (up to 4 control signals) Complete control of the welding process, including voltage, wire feed speed / current, gas, burn back and crater fill Teach & Play programming method with user friendly graphical interface Linear interpolation between taught points Up to 10 programs and 100 positions with welding parameters in each program Automatic configuration recovery after a power failure Automatic restart after a pause or emergency stop teach pendant common characteristics Can be connected to the robot or the control unit Color touch screen Emergency stop push button USB port for program and configuration backup Real-time display of the welding parameters Standard 2 meters (other length available) PleaSe ContaCt us to See HoW our MobIle PoRtable WelDIng RobotS Can HelP you SIMPlIfy your WelDIng automation PRoJeCtS! servo-robot inc Hocquart, St-Bruno Quebec, CANADA J3V 6E1 Tel.: Fax: sales@ SERVO-ROBOT reserves the right to change product specifications without notice SERVO-ROBOT Inc., All Rights Reserved. Printed in China. TMWRVS1308E01

9 AUTO-TRAC/ITTM COMPLETE SOLUTION FOR JOINT TRACKING AND ADAPTIVE PROCESS CONTROL DESIGNED FOR SPECIAL WELDING MACHINES ARC WELDING

AUTO-TRAC/ITTM COMPLETE SOLUTION FOR JOINT TRACKING AND ADAPTIVE PROCESS CONTROL DESIGNED FOR SPECIAL WELDING MACHINES AUTO-TRAC/IT TM SYSTEM TEACH PENDANT VIDEO CABLE

LASER-SENSOR CABLE ROBONET/DRIVE TM Z ACTUATOR (Drive and Encoder) ENCODER AIR HOSES INTERNET Y ACTUATOR (Drive and Encoder) COOLING UNIT LASER-SENSOR X-Z ACTUATORS X AXIS

Large selection of laser-sensors available to support specific processes and joint types. Immune to the Arc and Laser processes (spatter, heat, etc.).

High speed digital laser-sensor allows for fast and reliable joint recognition. Extensive to use with all industrial joint preparations. Automatic joint recognition.

10 AUTO-TRAC/ITTM COMPLETE SOLUTION FOR JOINT TRACKING AND ADAPTIVE PROCESS CONTROL DESIGNED FOR SPECIAL WELDING MACHINES AUTO-TRAC/IT TM SYSTEM TEACH PENDANT VIDEO CABLE ETHERNET TEACH PENDANT VIDEO SCREEN I/O OR FIELDBUS GROUND FAULT ROBONET/MASTER TM CAN-OPEN SAFETY LINKS FACTORY AIR IN COOLING CONTROL AIR FILTER KIT WELDCOM TM HMI INTERNET LASER-SENSOR CABLE ROBONET/DRIVE TM Z ACTUATOR (Drive and Encoder) ENCODER AIR HOSES INTERNET Y ACTUATOR (Drive and Encoder) COOLING UNIT LASER-SENSOR X-Z ACTUATORS X AXIS ENCODER CUSTOMER PLC FEATURES AND BENEFITS Fully integrated standard system with laser-camera, control unit, actuators, teach pendant and software. Large selection of laser-sensors available to support specific processes and joint types. Immune to the Arc and Laser processes (spatter, heat, etc.). Not affected by ambient lighting conditions. Can track on any weldable materials including aluminum. Pressurized air flow protects disposable lens against dust and fume. High speed digital laser-sensor allows for fast and reliable joint recognition. Extensive to use with all industrial joint preparations. Automatic joint recognition. With the use of the teach pendant, the axes position can be taught the same way as a robot. Adaptive process control firmware interface directly with the welding equipment. High speed, high accuracy rugged actuators for precise torch positioning.

EASY OPERATION Operation is made by the operator or by the PLC through an I/O interface. The operator uses the teach pendant to set-up and select the sequence, perform calibration and jog axes.

11 EASY OPERATION Operation is made by the operator or by the PLC through an I/O interface. The operator uses the teach pendant to set-up and select the sequence, perform calibration and jog axes. In addition, the teach pendant always provides the system status to the operator. With the teach pendant, the axes position can be taught the same way as a robot. AUTO-TRAC/IT TM CONTROLLERS The AUTO-TRAC/IT TM main controller is the ROBONET/MASTER TM. It is a powerful processing unit that manages the system sequence, the laser-camera profiles processing, the trajectory computation and the process adaptive control. A CAN-Open interface links it to the ROBONET/DRIVE TM controller which is driving the axes. Up to 3 axes can be driven and a fourth one such as a positioner, roller or gantry can be read. The system offers various possibilities to be interfaced with PLC s and different welding power sources through Digital I/O, analog signals or field bus. Teach pendant ROBONET/MASTER TM process control unit High-speed actuators (See complementary document) ROBONET/DRIVE TM brushless servo driver TYPICAL APPLICATIONS Fuel Tanks Pressure Vessels Bridges Structures Shipbuilding Wind Tower Turbines Water Heater Tanks Railway Car Pipe (Spiral and UO pipe) EXCLUSIVE FUNCTIONS AUTO-TRAC/IT TM is available for any joint preparation ranging from sheet metal tight butts to heavy plate complex grooves. The system drives motors with encoders thus providing in real time the current position of the welding torch in space. This provides to the system the possibility to be taught like a robot. Laser-Camera Taught Points Laser-sensor finding and action In addition, the encoders allow one to generate the proper trajectory while tracking, taking into account the travel speed, the position of the camera related to the torch and the current positions of the torch. The end result is a good weld that meets the most stringent quality requirements. The presence of encoders allows memorization of the joint trajectory which is a very useful tool to evaluate the part deviation that can be played back in multipass welding application. This also allows to monitor the part preparation to improve the quality. AUTO-TRAC/IT TM

LASER-CAMERAS TECHNICAL SPECIFICATIONS ARC WELDING LASER WELDING

(Field of view) DIGI-I/S MINI-I/D QUANTA/SP QUANTA/SP-350 QUANTA

6 mm Depth of field 65 mm 140 mm 120 mm 350 mm 6.

075 mm 0.09 mm 0.05 mm 0.23 mm 0.008 mm 0.015 mm 0.035 mm 0.

017 mm Weight 600 g 475 g 800 g 800 g 800 g 800 g Dimensions

3 113 x 145 x 40 113 x 145 x 40 113 x 145 x 40 113 x 145 x 40

: 5 to 40 C (41 F to 104 F) Laser : Class IIIb Very Heavy Plate

TM MINI-I/D TM QUANTA/SP TM QUANTA/SP-350 TM QUANTA TM QUANTA/LF

12 LASER-CAMERAS TECHNICAL SPECIFICATIONS ARC WELDING LASER WELDING Stand-Off from nozzle Close plane (Field of view) Far plane (Field of view) DIGI-I/S MINI-I/D QUANTA/SP QUANTA/SP-350 QUANTA QUANTA/LF 5.6 mm 5.5 mm 47.5 mm 93.9 mm 98.8 mm 93.8 mm 23 mm 27 mm 48 mm 66 mm 8.1 mm 15.6 mm 45 mm 76 mm 88 mm 194 mm 8.6 mm 17.6 mm Depth of field 65 mm 140 mm 120 mm 350 mm 6.5 mm 16 mm Average depth resolution Average lateral resolution mm 0.09 mm 0.05 mm 0.23 mm mm mm mm 0.05 mm 0.07 mm 0.13 mm mm mm Weight 600 g 475 g 800 g 800 g 800 g 800 g Dimensions (mm) 113 x 62 x x 58 x x 145 x x 145 x x 145 x x 145 x 40 Best Suited For Sheet Metal Heavy Plate Heavy Plate Environment : 5 to 40 C (41 F to 104 F) Laser : Class IIIb Very Heavy Plate (Pressure Vessels) Tailored Welded Blanks TIG Welding DIGI-I/S TM MINI-I/D TM QUANTA/SP TM QUANTA/SP-350 TM QUANTA TM QUANTA/LF TM TRACKING AND MONITORING SYSTEMS IN ONE PRDUCT! sales@ Servo-Robot reserves the right to change product specifications without notice Servo-Robot Inc., All Rights Reserved. Printed in Canada. TAUTTR0618E05.2

Introduction to Welding Automation

Introduction to Welding Automation This document summaries the Adaptive Control Methods By: Abdullah Alhuzaim 7/20/2011 Adaptive Control Methods: Touch Sensing Through-the-Arc Seam Tracking (TAST) -Single