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Progress in setting up our WAAM system for additive manufacturing: alignment of linear units, installation of the control panel, and quick-change system

The new robot-assisted WAAM system continues to take shape. In this construction phase, the focus was on the precise alignment of the KUKA KL 4000 linear units. These are mounted on the foundation with millimeter precision using a flexible screw system. The linear units serve as additional axes for the robots – a total of up to 16 synchronized axes can be implemented on this WAAM system.

At the same time, the control panel with integrated robot control was installed. This is used to control all movement axes of the robots and their peripherals.

A quick-change system including a CrashBox was also installed for efficient replacement of the welding torches on the robot arm. This consists of a quick-change head permanently installed on the robot and a corresponding adapter for the welding torch. This allows the welding torches to be replaced quickly and without tools as needed.

The CrashBox from Fronius is a safety device for robot operation. In the event of a collision, the CrashBox sends a signal to the robot controller, which immediately stops the robot. The CrashBox’s welding torch holder protects the welding torch from damage in the event of a collision.

Further progress in the construction of this state-of-the-art WAAM facility for additive manufacturing at the Chair of Joining and Welding Technology at BTU Cottbus.