Automated Multipass Heavy-Deposition Robotic Welding

Navus

One of our major contracts required welding large steel sheets for shipbuilding, which is typically a time-consuming endeavor, especially considering that the parts can weigh as much as 30 tons. However, with a multipass high-deposition robotic welding technique we were able to reduce the overall process time by about 60%.

Six ABB IRB 4600 robots, three on each side of the cell mounted on 30-meter tracks, move along using a Fronius GP tandem system. The robots work within two cells to achieve interpass cleaning, grinding, and removal of any silicate that could compromise finish quality.

The workpiece is a 2”-thick steel plate that must be flipped a total of four times for the completion of welding and cleaning between each pass. The welds require an interpass temperature of 200-300ºC, and cleaning must be completed before each pass.

Our engineers used RobotStudio to program the parts offline based on our client’s modeling software. Digital manufacturing with offline programming is essential in achieving a project of this scale.

With this system, our client was able to cut their manufacturing process from a minimum of 28 weeks to eight weeks for one key component, which reduces the overall build time per set of components by approximately 60-70%. Best of all, the increased productivity doesn’t come with any costs in quality. The robotic system has been qualified to complete UT (ultrasonic testing) class welds.

This project has been key to reaffirming our reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions.

Founded in 1998, Navus Automation, Inc. is an industry leader in full-service custom machine building and integration solutions. We collaborate with many Fortune 500 companies in the medical, automotive, military, and consumer industries. Navus engineers provide exceptional robotic solutions for integrated systems that increase productivity, quality, and safety.

 

Navus Authorized As SERVO-ROBOT System Integration Partner

Navus

Navus team members enjoyed meeting up with Servo-Robot representatives at FABTECH in November, 2016. Mike Teubert (Weld Engineering/CWI – Navus), Megan Gliebe (Sales & Administrative Coordinator, SERVO-ROBOT), Greg Hayzen (General Manager – Navus), Jeff Noruk (President –SERVO-ROBOT)

Navus Automation, Inc. has recently partnered with SERVO-ROBOT to deliver high performance robotic arc welding.

SERVO-ROBOT is a recognized world leader in intelligent welding automation. For more than 30 years, SERVO-ROBOT has been producing 3D robot-vision and sensing systems for welding and robotic automation. In particular, SERVO-ROBOT is a leader in the improvement of the performance of joining processes utilizing such technologies as laser seam tracking, laser seam finding, and automated weld inspection through a unique 3D laser vision technology.

Navus team members use SERVO-ROBOT’s laser seam tracker to locate and precisely scan even the most hard-to-reach joints. The laser scan maps each joint, making calculations on bead planning both more efficient and more effective.

Buck Barber, Sales and Marketing Manager at Navus, says, “Here at Navus, we have been working with SERVO-ROBOT for quite some time. With the use of their products, we have developed some of the most advanced welding technology on the market in terms of multi-pass and adaptive fill capabilities. In addition to the excellent on-board tools available with SERVO-ROBOT, we have also been able to use the platform to develop custom functions to take our solutions one step further.”

Founded in 1998, Navus Automation, Inc., is an industry leader in full-service robotic welding and automation integration. With a global reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions, we collaborate with many Fortune 500 companies in the medical, automotive, military, and consumer industries. Navus engineers provide exceptional robotic solutions for integrated systems that increase productivity, quality, and safety.

 

Navus Exhibited & Met With Key Partners at FABTECH

Navus

Navus staff members showcased their most innovative, custom-designed robotic weld system at the FABTECH trade show in Las Vegas, November 16-18, and met with key partners. General Manager Gregory Hayzen said, “Navus has become an industry leader integration applications, so we were very excited to share one of our most complex and customized systems with nearly 30,000 attendees, and to meet with some of our key partners.”

FABTECH is North America’s largest metal forming, fabricating, welding and finishing trade show event featuring world-class suppliers and the latest industry products and tools. While at the event, Navus team members also met with key partners including ABB, MeltTool, Servo-Robot, PushCorp, Inc., and ATI Industrial Automation.

ABB is a pioneering technology leader that is at the forefront of creating digitally connected and enabled industrial equipment and systems. MeltTool designs, manufactures and supports advanced visualization technologies for the welding industry. Servo-Robot produces robotic laser vision and sensing systems for welding and robotic automated manufacturing. PushCorp, Inc., manufactures robotic, compliant end-of-arm tooling, electric spindles and floor-standing equipment for automating material removal applications. And ATI Industrial Automation is a leading engineering-based developer of robotic accessories and robot arm tooling.

In collaboration with Navus, these partners and others are forging the future of integration systems and robotic designs.

Buck Barber (Sales & Marketing Manager – Navus) Mark Oxlade (Market Development Manager - Welding and Cutting – ABB) Josey Varughese (Controls Engineering – ABB)
Mike Teubert (Weld Engineering/CWI - Navus) Nicole Maturen (General Manager - MeltTools) Greg Hayzen (General Manager – Navus)
Navus team members enjoyed meeting up with Servo-Robot representatives at FABTECH in November, 2016. Mike Teubert (Weld Engineering/CWI - Navus), Megan Gliebe (Sales & Administrative Coordinator, Servo-Robot), Greg Hayzen (General Manager – Navus), Jeff Noruk (President – Servo-Robot)

Watch our time lapse video of activity at the Navus booth.

See Us In Action

Navus

We invite you to view two new videos on our website that showcase our innovative work.

The first video features an unprecedented welding project that was designed to move a robotic welding workcell 20 yards into position in a dangerous environment. This multi-task robot effectively preps joints, welds, provides inter-pass cleaning, and vacuums welds remotely from an operator’s console that utilizes a live monitor and a HD camera for post inspection.

Navus services include precision CNC machining as well as the prototyping, fabrication and assembly of metal and composite materials for aerospace, automotive, medical device, nuclear, and pharmaceutical applications. Our commitment to quality is the result of having qualified personnel dedicated to meeting our goal of serving the customer.

Navus To Exhibit Multi-task Robot At FABTECH 2016

Navus

Tactical Welding SystemOn the heels of being awarded a globally competitive contract, members of the Navus Automation, Inc., team will travel to Las Vegas to exhibit their most innovative, custom-designed robotic weld system at the FABTECH trade show, November 16-18.

General Manager Gregory Hayzen says, “Navus has become a strong industry leader in forging the future of integration applications, and we’re excited to share one of our most complex and customized systems with nearly 30,000 attendees.”

The unprecedented welding project was designed to move the robotic welding workcell 20 yards into position in a dangerous environment. The multi-task robot effectively preps joints, welds, provides inter-pass cleaning, and vacuums welds remotely from an operator’s console that utilizes a live monitor and a HD camera for post inspection.

Navus provides state-of-the-art robotic welding and cutting machine design and integration, programming and controls automation, and custom fabrication to some of the finest companies in sectors including:
• Defense
• Shipbuilding
• Aerospace
• Automotive
• Power
• Medical
• Glass Forming
• Consumer Manufacturing

FABTECH is North America’s largest metal forming, fabricating, welding and finishing event. The trade show features world-class suppliers such as Navus, the latest industry products and developments, and tools to improve productivity, increase profits and discover new solutions to metal forming, fabricating, welding, and finishing needs. The annual event hosts more than 1,300 exhibitors and 28,000 attendees for three days at the Las Vegas Convention Center.

Navus Enters A New Realm In Innovation

Navus

navus-logo-trans
—By General Manager, Greg Hayzen

Since forming nearly 20 years ago, Navus has grown steadily and solidly to become a leading full-service automation integrator. The past few years have catapulted us to a new level of world-class excellence after we’ve successfully delivered seemingly impossible customized turn-key solutions to extremely difficult challenges.

Through ingenuity, our resourceful and determined team has taken on larger integration challenges and has continually succeeded in delivering robotic welding and automation systems that go above and beyond what each customer requested.

After one customer remarked that we achieved a solution that no one else ever had, we realized that we had entered a new realm in innovation. By clarifying the most complex challenges, Navus is positioned to forge the future of systems integration.

As an outward reflection of our inward growth, we’ve modernized our logo, our website, and our tagline—Forging the Future, Clarifying the Complex. We are excited about what the next 30 years might bring, and we look forward to working with you in the future.