Wallwork Group has invested £100,000 to introduce a Universal Robots’ (UR) collaborative robot (cobot) to its vacuum braze line in Cambridge which will make high-volume braze components a commercially viable option for many manufacturers.
Wallwork Group director Simeon Collins said: “Cost-effective, high-volume vacuum braze components have been out of reach until now — largely due to the amount of assembly and labour time required. This investment brings the advantages of vacuum brazing to components that were previously uneconomic to process. It also means we can develop the quality of customer products.”
Wallwork’s Chris Osborne and Odhran Mcbride oversaw the installation. Mr Osbourne said: “The medium-size cobot is capable of manipulating a 12.5kg payload, with a 1,300mm reach. It will work alongside our skilled braze operators and has the ability to learn as it goes along via a continuous improvement process. Customers will enjoy higher-quality levels not seen before. Accuracy, consistency and repeatability are assured.”
Further investmentThe use of robotics also makes 24hr braze application a reality, increasing service availability. Success with the UR cobot is likely to spark further investment in the technology. Mr Mcbride added: “We are looking forward to vacuum brazing the first batch of customer components with the cobot. This is scheduled for the beginning of October.”
Preparing components for vacuum brazing requires great skill and attention to detail, and the cobot is able to replicate this manual process by creating complex components by joining simpler parts made from similar or dissimilar materials. A braze metal with a lower melt-point flows by capillary action into the space between the components. The filler metal or alloy is heated to a temperature above 750°C, and this forms an exceptionally strong, sealed and leak-proofed joint.
Furthermore, the cobot process is clean and flux-free and produces high-strength components with excellent dimensional stability. These are free of voids or inclusions, resistant to shock and vibration and able to withstand high pressures. Wallwork is also able to heat-treat components at the same time, which realises further cost advantages to customers, and with a dedicated pick-up and delivery fleet, speedy order turnround is assured.