Above: The Blaze robotic laser welder requires no programming, complex axes, reference frames or
integration.
April, 2024- Food service and beverage equipment manufacturers covet stainless steel for its durability, corrosion resistance and aesthetic appeal. Welding the alloy particularly thin sheet can be problematic due to its
high melting point, low thermal conductivity, and susceptibility to distortion and warping. Finish and appearance are critical requirements for companies like Associated American Industries (AAI). The Middleby Corp. subsidiary produces subassemblies and sheet metal parts for sister company brands such as Lynx, Viking, Taylor, Blodgett, Bakers Pride, Turbo-Chef, Synesso and Wunder-Bar. Based in Elgin, Illinois, Middleby develops and builds solutions for commercial, residential and industrial food service equipment, and has built a reputation as a technology disruptor and innovator.
Looking at ways to boost productivity, improve weld consistency and reduce the need to grind and blend welds, AAI partnered with another technology disruptor by becoming the test site for Productive Robotics’ new Blaze robotic laser welder.
“For the right applications, laser welding off ers a number of advantages, especially when it comes to thin sheet work, which traditionally has been performed with TIG welding,” says Zac Bogart, president of Productive Robotics. “Typically, laser welds generate less post-weld finishing because the weld bead is smaller or non-existent. Too much welded metal can cause cracking or warping.”
Unlike conventional 6-axis robots, the 7-axis Blaze gives the operator a maneuverability that
results in simpler fixturing and fewer re-fixturing setups.
An unlimited library of welding recipes and a “no programming” drag-anddrop tablet controller
allow Blaze to learn any job in minutes.
NO PROGRAMMING
“We approached AAI as a testing ground for our new product because they produce an enormous variety of stainless steel parts,” Bogart continues. “Cosmetically, their market only accepts perfection. They touch every possible variation of weld and sheet geometry. Working with AAI allowed us to test every weld type and get invaluable feedback from seasoned experts.”
The Blaze robotic laser welder requires no programming, complex axes, reference frames or integration. An unlimited library of welding recipes and a “no programming” drag-and-drop tablet controller allow the robot to learn any job in minutes, from simple to complex paths.
Unlike conventional 6-axis robots, the 7-axis Blaze robotic laser welder gives the operator a maneuverability that results in simpler fixturing and fewer re-fi xturing setups.
“You can teach Blaze to weld faster than you can do the weld manually one time,” says Bogart.
AAI initially tested the robotic laser welder on stainless microwave cavity weldments, residential exhaust hood components and other stainless steel food service equipment weldments. “We were able to achieve more consistent welds with less heat distortion,” says Doug Hornbeck, vice president of operations and general manager for AAI. “We reduced secondary processes such as grinding and blending. We also gained the ability to perform an outside corner fillet weld. It was a type of weld that our operators found challenging with a handheld laser welder.”
In addition to outside corner fillet welds, operators can perform long continuous welds on light-gauge stainless steel and have reduced spot welding on awkward cavity weldments.
“We also found we achieved better aesthetics with our welds,” notes Adalberto Romero, plant manager for AAI.
Food service assemblies made from stainless steel grades 304 and 430 in 16- to 22-gauge comprise the majority of products AAI is processing with its Blaze robotic laser welder. The system is running six to 10 hours a day performing fillet, butt and seam welds.
Blaze uses recipes to automatically control welding parameters and settings. Recipes for common weld materials and weld types are preprogrammed, with an unlimited number available. Complex jobs may include multiple formulas which are automatically adjusted during welding. This approach gives the operator greater weld control versus manual methods. Blaze has a reach of 61 in. and requires 220v power. “We needed the Blaze robotic laser welder to be as simple and fast to use as our MIG systems,” says Bogart. “Our MIG systems can be taught to weld faster than an operator can perform a weld manually. The automated laser welding system had to meet that performance standard. We also needed to be able to change weld parameters [or recipes] on the fly while the torch is moving. This is critical for rounding corners to minimize post weld finishing.”
With this new product, “our robot talks directly to the laser system controlling every aspect of a job’s welding parameters,” Bogart says. Romero notes that operator response to the Blaze robotic laser welder
has been positive.
“The initial fear personnel typically show for new technologies didn’t last long,” he says. “The robotic laser welder requires less training. Once they got the hang of it, our operators enjoyed how easy it is to use.”
In an industry that doesn’t allow for errors, AAI’s decision to incorporate new robotic laser welding technology in its fabrication operation has reduced labor costs, enhanced cosmetic appeal, and provided higher throughput and process improvements for the parts supplier.
Associated American Industries, 052-631-320-7880
