Super Structure Repair

super1

One of the latest innovations to come from Carbines Engineering is the process for repairing contact faces on the “Cell Superstructure Buzz work”. The worlds largest commercially manufactured articulated robots from Motoman were selected for this operation, after all it would have to carry out a process that no one was aware of having been done before. “Use a 200mm surface cutter to mill an aluminium face to N6 or 0.8 micron quality finish and be Mechanically Separate from the work piece”.

Why would anyone require such a system? Because the robot not only pre-mills the face, it also rebuilds it! Using a Mig welder, it then lay’s on weld to the face, before finish milling it. The smoothness of this operation does tend to hinge on how well prior welding has been done to these faces, as it is difficult to weld correctly if the base metal is badly composed. All things being equal, however, the system can accommodate angled faces etc. by having the robot sensor-search the face and change its welding and milling positions to suit Buzz work distortions along with reasonable Superstructure placement. After all it is rather difficult to accurately place 14 tonnes of superstructure in front of a robot.

With a robot on each side of the repair tracks the supers are driven to a position where both machines can access at least 4 faces, the operator then selects the most appropriate grade of program for each face. The robots then machine and weld the faces without further operator intervention.

Face after welding

Face after welding

Face after milling

Face after milling