New Era of Intelligent Riveting and Welding | KEBEI Riveting and Welding Work Island Helps Steel Structure Manufacturing Enter the Era of “Zero-Intervention Intelligence”

In the field of steel structure manufacturing, riveting and welding process is the core link, but the traditional mode of operation has long been faced with a high dependence on labor, high fluctuations in efficiency; poor operating environment, safety hazards; high comprehensive costs and other problems, product quality and consistency is difficult to ensure that the production efficiency is difficult to meet the growing market demand.

 

 

It is in this industry background, KEBEI laser developed a revolutionary riveting and welding island. With intelligence, high precision and zero intervention as the core, the riveting and welding island seamlessly integrates the two major processes, realizing the seamless connection and efficient synergy of riveting and welding processes.

It is suitable for automatic riveting and welding of reinforcement plates and partitions in H-beam and U-beam with large production volume in steel structure and other industries, and can work continuously for a long time with high production efficiency.

The automated production method of KEBEI riveting and welding island, importing the TEKLA model of the product, the intelligent control system can automatically recognize the drawings and automatically plan the position of the reinforcement plate and the trajectory of the weld seam, eliminating the need for manual measurement, no need for scribing and positioning, and directly eliminating the need for riveters.

 

 

At the same time, the work island can first find the edge of H-beam according to the set movement path, and this operation greatly improves the precision of the work island in the welding process.

 

 

 

In the riveting process of the bar plate, the equipped high-precision electromagnetic suction cups can automatically grab the bar plate and push the wing edge of the section steel through the oil cylinder, which can effectively prevent the bar plate from being stuck during the placement process.

 

 

 

The riveting process adopts an intelligent control system, which can automatically identify the drawings, plan the position of the fascia plate, and realize ±1mm high-precision riveting, ensuring the stability and consistency of product quality. Automated riveting and assembly frees workers from repetitive and heavy physical labor, avoids possible errors in manual riveting and assembly, and significantly reduces the risk of work-related injuries.

The welding unit is the core of the operation island, undertaking the task of high-quality welding of riveted components. The unit is equipped with advanced welding robots, which can automatically recognize the trajectory of the weld seam according to the preset welding parameters and carry out precise spot welding and full welding operations.

 

 

 

During the welding process, the robot moves smoothly, the weld seam is beautifully shaped, and the welding quality is stable and reliable, in full compliance with the industry standard.

 

 

The overall welding time is several times shorter than that of manual welding, and it is safer and smarter. The whole process does not require manual participation, only computerized operation, the robot can complete efficient welding, workers do not need to face the welding operation in close proximity to the sparks, eliminating the need for a harsh operating environment.

 

 

After completing the welding work, the welding cell also has the function of automatic gun cleaning, after the completion of welding, the welding gun will be automatically cleaned, and all kinds of equipment will automatically return to the “zero point” position, ready for the next operation, truly realizing the whole process automation.

 

 

The emergence of KEBEI's riveting island has completely changed the traditional riveting operation mode. In traditional riveting production, a single production line needs to be equipped with 4 welders + 2 riveters, with an average monthly labor cost of about 60,000 yuan (calculated according to the industry average salary of 10,000 yuan/person/month), and the efficiency fluctuates by 30% depending on the proficiency of the workers. With the introduction of riveting and welding operation island, only 2 workers are needed for a single machine, and the labor cost is reduced from 60,000 RMB/month to 20,000 RMB/month.

 

 

A riveting and welding island not only significantly reduces labor costs, but also increases productivity several times. In the future, through the two-shift operation mode, the productivity can be further increased by more than double.

What's more, the application of the work island effectively improves the welding working environment, liberates workers from the harsh environment of high temperature, noise and dust, protects workers' health, and promotes the transformation and upgrading of the steel structure manufacturing industry in the direction of intellectualization and greening.