How To Increase Productivity while Decreasing Floor Space with Multi-Axis Welding Positioners

The greatest benefit of adding multi-axis positioners to a production process is increased productivity, when compared to using robots with one fixed position. Positioners give the robot better access to tooling or parts, reduces floor footprint while maximizing throughput. They allow parts to be removed easily, and gives the company flexibility to add multi-stations. Multi-stations provide the advantage of allowing the production staff to switch parts faster and minimally without a lot of downtime.

This is especially helpful for the manipulation of large parts during welding, such as aircraft wings or rail cars, which need to be welded and or painted on multiple sides. With multi-axis robot positioners flipping parts over can be achieved precisely without antiquated and costly cranes and jigs.

The physics of Multi-Axis Welding Positioners are different from standard rotary tables. Instead of having the load capacities rely on the inertial loading and bearing capacities, a weld positioner is dependent on the static torque output limitations. A welding positioner system that is designed for efficiency will be balanced to move heavy weights at surprising speeds, consistently producing high-quality welded products. 

The best headstock tailstock trunnion weld positioner sets utilize a high precision zero back-lash cam operated rotary index table mounted in a vertical position complete with mounting.  There is the option to purchase a complete trunnion solution that includes heavy duty constructed base frame, HS/TS riser bases, and fixture backbones. The machines should be painted to meet industry standards including specialty paints for corrosive applications if required and completely sealed machine surfaces to eliminate intrusions.

Weld Positioners have large through holes to run utilities to the tooling and fixtures, easy access to pipe and wire all components and standard models available to quickly initiate the design process. They can have custom controls and pre-programmed panels to create a more flexible automation system and can be paired with robotics to accelerate productivity. You should have a choice of robot manufacturers for your project. Systems integrators that have freedom to choose the robotics manufacturer can adapt to their customers’ requirements, minimizing design costs from project to project. 

Be Sure that Your Weld Positioner Manufacturer:

• Can accommodate all servo motor and robotic motor brands

• Can operate from standard AC motor single or three phase

• Headstock (flexible or fixed index drive, with or without drive motor, servo or AC)

• Tailstock (bearing assembly or thru-hole bearing housing)

• Custom Risers and Center Frames 

• Optional controls drive for motor

• Micarta isolation kits for specific welding applications

• Black oxide head and tailstock mounting flanges

The best weld positioner manufacturers offer features that extend machinery life and reduce operating and maintenance costs. Examples are:

• Flame hardened cams

• Multiple oversized cam followers engaged with cam at all times

• Programmable rotation angles of both base rotary movement and dual trunnions

• Fixed central guarding between both trunnion sides

• Fully maintainable with all wear components capable of being serviced at facility

• Very low maintenance components

For material shuttling and transferring, LazerArc by Motion Index Drives has engineered a multi-axis positioning system that utilizes a high-precision helical rack and pinion covering any distance while achieving extremely high accuracy and repeatability. LazerArc Multi-Axis Welding Positioners provide a superior index time, and flexibility to meet the demands of modern automation systems. These complete 3, 4, or 5 Multi-Axis Welding Positioner machines are designed and engineered to provide superior performance in demanding industrial automation environments. LazerArc positioning systems utilize one of two mechanical drive systems depending on customer requirements. Our high capacity “zero backlash” programmable cam systems create extremely high accuracies and repeatability of 2-3 arc seconds, while providing mechanical robustness to suit any size application. All trunnion units can be ordered with standard or custom frames fully equipped with head and tailstock supports and one-piece base weldments. A big benefit to integrators is that our systems can adapt to any robot manufacturer their end customers are dictating to use. Our Robotic Welding Positioners are ideal for rollover applications in the aerospace, automotive, defense, construction and mining equipment, alternative energy and railroad transportation manufacturing environments.