Bisiach & Carru (Italy)

The paper describes how a gantry robot, used in the railway industry, has been adapted to allow the installation on the robot head of an innovating sensing system, whose integration has highly improved welding and milling operations on huge wagons' surfaces during the crate's assembly phase. The robot required specific modifications in order to be extended with the sensor equipment, promptly responding to signals for measuring the geometric features; the length sensitive wire strains or capacity elements are also evaluated for controlling the milling process required for cutting the openings (doors, windows, etc.), due to an automatic tool changer. The automation out of the wide aluminium panels relates to two steps, following the integral manufacturing approach: (1) MIG welding of extruded aluminium profiles; and (2) joining modules to the wagon crate. Therefore an interesting configuration has been designed, where the gantry robot has been placed/mounted. The definition of standard interfaces is one of the major topics of the described technology, as well as the possibility of realising standardised universal devices, ready to be used in all conditions. As an economical effect, consistent improvement of pieces per time-unit and a reduction of operating costs because of the lower dead time have been achieved. The technology transfer is applied to an integrated pilot-cell for welding and milling.