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The application of collaborative robots with welding vision-based teachless technology in container manufacturing utilizes the robots’ lightweight, flexible, and safe characteristics. Combined with 2D laser sensors and a 3D vision system, the robots automatically identify weld seams for automated welding on the production line.
The system includes the robot, control cabinet, vision system (3D camera, industrial computer, vision software), welding machine, wire feeder, and welding torch, integrated into the PLC control of the production line. The robot is mounted on a base or movable stand, enabling human-robot collaboration without protective fences, saving space. Using vision-based teachless technology, 3D cameras or 2D laser sensors capture point clouds to automatically correct positioning deviations, eliminating manual teaching and improving efficiency and accuracy.
1. Labor Savings and Production Efficiency Improvement: By upgrading the assembly line and deploying around 60 collaborative robot welding vision stations, the workforce requirement for welders is reduced by approximately 60 people. Improved welding quality also reduces post-welding and grinding tasks, saving about 10 more workers in the process.
2. Addressing Labor Shortages: This solution effectively alleviates the long-standing “welder shortage” and the aging workforce issues in shipbuilding, while liberating frontline workers from high dust and intense arc radiation environments.
3. Promoting Enterprise Transformation and Creating New Technical Roles: The human-robot collaboration model has fostered new technical roles such as “robot maintenance engineers,” driving the transition from traditional “manual” welders to “technical” operators.
4. Verifying Feasibility of Large-Scale Collaborative Robot Deployment and Reliability of Domestic Equipment: The deployment of 60 visual welding robots in a cluster verifies the feasibility of large-scale collaborative robot applications in complex scenarios. It also demonstrates the reliability of domestic intelligent equipment in heavy-duty and non-standard tasks. The project recovers its investment and becomes profitable within a year, providing a quantifiable, replicable model for cost reduction and efficiency improvement in industries like container manufacturing.
This project has enabled significant improvements in both production efficiency and quality through in-depth process adaptation and system optimization for container manufacturing. By deploying 60 collaborative robot welding vision systems, it successfully addressed the flexibility challenges of traditional industrial robots in compact assembly line layouts while solving the consistency issues of manual welding. The collaborative robots work closely with operators without the need for safety fencing, perfectly adapting to the space constraints of Ningbo CIMC’s production line.
Additionally, the project achieves rapid switching for multi-product batch production, with modular process packages that support one-click calling of welding programs, reducing changeover time from several hours to just minutes, realizing true flexible automation. SIASUN DUCO’s technological innovation not only boosts production efficiency but also promotes employee skill transformation, transitioning workers from “manual” to “technical” operators, solving labor shortages and enhancing employee value.
Through the “cluster collaboration” model and the “co-creation of processes” approach, this project provides a quantifiable, replicable cost-reduction and efficiency-improvement solution, helping the customer move toward a more efficient and intelligent production model.