A manufacturer of emission control systems for mobile and stationary internal combustion engines had been experiencing rework issues and required a more consistent process for welding silencers, catalytic converters and other large cylindrical-shaped emission controls components.
The customer's main facilities are located in Toronto, Ontario, Canada and they had previously implemented semi-automated column and boom welding manipulator systems with excellent results. With an expansion into the Texas, USA market, the company came to LJ for another system - including full material handling - to build on their previous successes that included faster cycle times, higher quality welding, and drastically reduced rework.
All the equipment was previously fabricated using manual MIG welding processes, along with conventional rollers, cranes, labor-intensive methods for lining up the sections during welding and fit up. This left room for error and rework costs were jeopordizing the facilities long-term profitability and competitive edge.
Within four months, LJ consulted, process-audited, delivered and commissioned a fully automated welding cell that included the following:
Turnkey system: included tank turning rolls, track drive systems, CaB manipulator and welding package, fully integrated.
Integrated Controls: system start/stop, welding and vessel rotators controlled from the column and boom manipulator HMI or remote pendant.
Operator's Platform for ease of control and visibility when welding.
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