YAMATO BRAZING MASTER III
Do you have any problems in automation & labor-saving in brazing machines or robots?
Torch Brazing (Gas Brazing) Robot spec.
Overview
A brazing robot which we have developed this time, on the premise that the robot is an articulated 6-shaft type, is a torch brazing (gas brazing) model. The 6-shaft robot is equipped with a burner and wire feeding unit. It has a burner, a wire feeding torch with a small-sized air cylinder, a high-precision workpiece temperature sensor and a jig temperature sensor as standard equipment.
Various conditions inputted into Brazing Master from the robot program are controlled by sequence controll.
Structure
(1)Brazing Master
(2)Wire feeding device stand
(3)Burner unit
(4)Ignition device
(5)Vapor tank
Others
Workpiece temperature sensor
Jig temperature sensor
1 set as standard equipment the above
Specifications
Type Brazing Master Ⅲ
Power 200 V Single phase / Air pressure 4Mpa
Gas Flammable gas（LPG LNG Acetylene Hydrogen etc.）＋Oxygen
Flux Supply Gas flux type Vapor tank
Wire Feeder Oriental controller motor Wire diameter: 1.2DIA. Standard size
Controll Sequencer Touch Screen: Mitsubishi Electric
Robot Input / Output Input: 15 points, Output: 15 points
There is a little difference among manufacturers.
Options
1. Robot manipulator controller & Annex
2. Shock sensor
3. Starting call system
4. Frame for equipment & Safety measures
5. Other functions & Additional peripheral equipment
It is
YAMATO Brazing Master III
that can sweep away such annoyance.
Do you have any problems in automation & labor-saving in brazing machines or robots?
We often hear about the following problems in production sites.
· Quality and production quantity tend to depend on operators’ skill.
· It takes time to restore auto operation after a temporary stop and a changeover.
· To get rid of a repair process.
· After-sales services by manufacturers are not provided promptly.
· It takes time to obtain replacement parts, spare parts, and small parts, etc.
· There are few cooperative companies with which you can have technological consultations about improvements of existent equipment and specifications which are suitable for a working site.
· To automatize manufacture in small quantity and many kinds.
· To promote automation in order to make up for a shortage of skilled workers.
It is YAMATO Brazing Master III that can sweep away such annoyance.
Solution.1 Stabilization of Fire Power
It is possible to set and display a high-performance flame control and a control of the instant change in gas flow rate by numerical value input/output control. Even though the outside air temperature environment and pressure is changed, a stable fire power can be maintained because the gas flow rate is measured by the mass (measured by not the volume of gas, but its molecular weight).
The ratio control flames such as a high flame (heating), a neutral flame (filler metal feeding), and a low flame (It is possible to set and control an oxidizing flame, a neutral flame, and a reducing flame.)
Flammable gas (Acetylene, Ethylene, LNG, LPG, Hydrogen) ＋ Oxygen or Air
Solution.2 Timely Heat Input Control
Program steps are executed by measuring the temperature of an actual workpiece as a processing object instead of setting a timer uniformly. Also, a heating time and the inclination of a gas flow rate are automatically corrected by measuring the heat input influence of the jig contacting with a workpiece.
Solution.3 Smooth Wire Feeding
A brazing filler metal does not reach a brazing point properly or a buckling happens.
It is possible for a control motor and the cooperative automatic correcting function between a workpiece temperature sensor and a jig temperature sensor to feed a brazing wire smoothly.
Solution.4 Brazing Conditions by Numerical Control
To control brazing conditons with a numerical value without depending on operators’ intuition and experience.
It is possible to control the brazing numerical conditions gradually according to the production lot of a workpiece and the change of a working environment, and to cope with the production at night and a foreman’s absence, and to maintain a stable production by limiting selection range from workers’ screen.
Solution.5 Stable Quality in Brazing
At the time of automatic operation, “the spread of a brazing filler metal” is not sufficient.
At continuous operation, “a welding burn” becomes intense, and results in the poor appearance.
It is possible to stably keep fillet shapes of filler metals which are indispensable for promoting heat transfer and ensuring airtightness and strength with automatic correction by the temperature sensing function the mentioned above instead of uniform continuous operation.
Solution.6 Reduction in Costs
To reduce the costs, for example, the consumption of gas.
A waste can be eliminated by smoothly controlling the extinction with standby flame, and by setting from small flame to preheat (high heat).
To change to multi specifications in ring burners, to review the number of burner tips and, to make a heat input effective by equipping a swing function with a brazing machine.
Changing acetylene or ethylene to hydrogen（premix) + oxygen in a flammable gas to use in equipment, leads to not only reduction in monetary cost, but good quality, longevity of consumables and relief of a burden on workers.
*The matters in the above could not work enough by the shape of a workpiece and the conditions you present.
It is YAMATO Brazing Master III that can provide the best production equipment with you by making good use of a system we have built and peripheral equipment.
Technology of Torch Brazing（Gas Brazing）is …
So far, it has been believed that brazing using a flame needs “intuition and knack”of highly-skilled workers, and in automatic brazing machines and robots as well, skilled operators have to cope with a changeable working environment, otherwise, it would be difficult to stably produce a good item.
The important POINTS in brazing are…
· Heat input temperature control of brazing points
· Flame control and its switching control
· The best feeding control of a brazing filler metal
· Stable supply of flux
· The other
It has been also believed that it is difficult to produce a machine which includes the POINTS above with accuracy at low cost, but…
It is YAMATO Brazing Master III that can provide the best production equipment with you by making good use of a system we have built and peripheral equipment.
YAMATO Brazing Master III monitors and controls in 3 basic points!
Evolution.1 Flame Control
A flame is controlled by detecting the mass of gas instantly instead of setting the flow rate based on the volume of gas. Therefore, it maintains a stable flame in spite of the temperature and pressure change of a working environment. It stabilizes the best flame in a brazing process such as a high flame (heating flame / oxidizing flame), a neutral flame (reducing flame / brazing flame), a low flame (standby flame / extinction & ignition), and a ratio control flame. Besides, it is possible to memorize several kinds of patterns of adjusting a proper gas flow rate with a touch screen and to adjust the best gas control even in automatic operation.
In the past, it was necessary to adjust a gas flow rate at any time according to a working environment, and also it was important for skilled operators to keep a reducing flame at the time of feeding a brazing wire.
However, YAMATO Brazing Master III enables even beginners in brazing to carry out the automatic operation easily.
In addition, YAMATO brazing Master Ⅲ is able to set some ratio control flames needed for a brazing process by a workpiece you present. It is also able to maintain a stable spread of a brazing filler metal (a fillet shape) by making good use of a temperature sensing function to control a heat input instantly.
Evolution.2 Heat Input Temperature Control & Cooperative Automatic Correction
YAMATO Brazing Master III is controlled by a workpiece (processing object) temperature sensor.
It feeds a brazing filler metal by making good use of an infrared temperature sensor which detects the best temperature to feed it.
It is possible to set the upper and lower limit of the best temperature range for brazing. Under continuous monitoring, when some abnormality occurrs, the cause is displayed in a monitor.
· Correcting control by a jig temperature sensor
· Check a jig heating curve and set correcting control conditions.
YAMATO Brazing Master III avoids the defects in a poor spread of a filler metal and a welding burn by checking a workpiece temperature sensor and by automatically correcting a preheating time and a gas switching time.
Jig Temperature Display
It inspects a jig temperature and the defects in a poor spread of a brazing filler metal and a welding burn, and keeps a stable production by setting the lower and upper limit temperature. It also inspects the heating curve of a jig temperature, and controls a heating time and gas switching.
Workpiece Temperature Display
It displays a set temperature value and a present value instantly, and controls a suitable temperature range in the feeding of a brazing filler metal.
Evolution.3 Brazing Filler Metal Feeding Control
A cooperative automatic correcting function between a workpiece temperature sensor and a jig temperature sensor, corrects temperature the best at any time, and then the wire feeding control in YAMATO Brazing Master III feeds a brazing filler metal.
Jig Temperature Heating Curve
〔 Jig ex. 〕Setting of the control range
Normal temperature 20° － 200° Max
The variation of a jig temperature in continuous operation
30° － 180° correction 4.5 sec. － 0.5 sec.
Brazing filler metal feeding temperature
Range: 800° － 900°
Wire Feeding Control Optional Functions!!
Touch Feeder
It prevents a workpiece from buckling by an insufficient heat input to a brazing filler metal and avoids a short supply of it at the time of adjusting brazing conditions. It copes with an insufficient heat input to brazing points by workpiece dispersion in precision by the production lot.
Smooth Feeding
It prevents running short of a brazing filler metal and its dripping, and stabilizes fillet shapes of brazed joints by setting an instant feeding change such as a high and low speed, a feeding cycle, and a stop. It is possible to set several kinds of patterns with a touch screen, and add or change them.
Retracting Function
It prevents a brazing wire from sticking a workpiece, and avoids the burn-through of a ball formed on the tip of the wire at the time of adjusting brazing conditions.
Like the mentioned above, it is possible to select the best condition with a touch screen.
It controls the sticking length of a brazing filler metal in the complex shapes and structures of workpieces and jigs, and avoids the problems above.
In addition, we are ready to offer various versatile optional functions!!
Challenge.1 Gas Flow Rate Unitary Setting
· A standard neutral flame (reducing flame) is displayed by using an oxygen and flammable gas mixing ratio setting function. This becomes a standard for setting a high heat (oxidizing flame) and a low heat (standby flame). Thus, it is possible for beginners to set a flame easily.
Challenge.2 Flux Control
· The consumption of flux is properly controlled by providing a bypass circuit with a vapor tank.
〔ex.〕We succeeded in saving up to 30% of the consumption of flux in a working environment at approximately 30°.
· A concentration sensor detects the evaporation amount of a vapor tank, and tells operators the timing of its replenishment.
Challenge.3 Gas Piping Inside Cleaning
· The residual of gas flux collects inside flammable gas piping, carbon inside a burner and a backfire prevention device. It has a bad influence on flame control. When starting or finishing automatic operation, they are kept clean by automatically purging the residual with nitrogen or air.
Challenge.4 Preheating Operation Bypass
· This function is provided with a bypass circuit so that flux will not adhere to a jig at the time of preheating operation. It heats up to a setting temperature.
*The standard specification model contains a preheating operation function.
Challenge.5 Gas Replacing Function
· In case air is mixed in equipment piping after injecting flux and temporarily stopping the equipment for a break, manual operation is carried out in order to control gas properly. Thereby, the state of a flame at the time of starting returns to the normal condition, and it prevents the flame from backfiring.
*The standard specification model contains a preheating operation function.
Challenge.6 Gas Discharging with One Stroke
· This function discharges the residual gas in equipment piping and a vapor tank in several seconds after finishing the work. It prevents the residual of flux from adhering to them during the stop of the equipment. Also, it escapes a back flow gas by an error in operation at the time of starting the work.
*The matters in the above could not work enough by the shape of a workpiece and the conditions you present.
We will propose an operator system which is convenient for you and suitable for your working site.
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Operation Screen
· Monitor and display both a specified value and an effective value. |
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Temporary Stop
· Display the cause of a stop. |
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Alarm History
· Display the cause of a stop. |
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Various Functions Conditions
· Display settings and selection situation. |
