2009-01-valk mailing-en

8
The official opening of Valk Welding France Atlantique on 15 May means that Valk Welding has now extended its activities to Western France. Under this name Valk Welding in Saint-Nazaire, with four French-speaking speci- alists, will be actively entering the market in the western region of France with demos, sales and service for welding robots and the sale of welding accessories. The welding accessories of Valk Welding are kept in Saint-Na- zaire, where a number of welding robot systems are permanently set up for demonstrations of both Panasonic and Fanuc robots. Valk Welding has already been selling and installing welding robot systems in the north of France for a number of years. Valk Welding has now delivered more than sixty welding robot systems to local French companies in that area, as well as to international compa- nies including Bosal, Thule, CNH, Dhollandia and Mecanorem. Valk Welding is setting out to increase its sales of welding robot systems in France by working in close partnership with local specialists. The official opening was conducted by Remco H. Valk (CEO Valk Welding Group), Michel Devos (sales manager Valk Welding France) and Olivier Moyon, Romuald Thomère, Etienne Menard, part- ners Valk Welding France Atlantique. Valk mailing a publication of Valk Welding 9th year - 2009 - no 1 © Valk Welding BV, 2009 Alle rights reserved. Also in this issue: Valk Welding France Atlantique opens in Western France Replacement programme makes investment in the latest welding robot technology an attractive option . . . . . . . . . . . . . . . . . . . . . . . 2 Options for Tawers welding robot for alumi- nium further extended . . . . . . . . . . . . . . . . . . 2 Demo, training and service for East European market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 • Crucial parts safely stored in new depot . . . 3 Bollegraaf switches with welding robot cell to single-article production . . . . . . . . . . . . . . 4 Faymonville installs Panasonic manual welding machines throughout organisation 5 • Combined arc/stud welding robot for VDL . 5 Joskin raises productivity with latest welding robot technology . . . . . . . . . . . . . . . . . . . . . 6-7 Marko installs fourth generation welding robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fabrice Lefèvre, pivot between a French client and the Valk Welding organisation. . . 8

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Valk Welding is a trend-setting supplier of products and services in the field of industrial robotics and welding techniques. Based on its extensive assortment, and its unique know-how and experience in the field of both robot- and welding techniques, Valk Welding is able to supply overall solutions that will increase your productivity and performance. Valk Welding: The strong connection!

TRANSCRIPT

Page 1: 2009-01-Valk Mailing-EN

The official opening of Valk Welding France Atlantique on 15 May means

that Valk Welding has now extended its activities to Western France Under

this name Valk Welding in Saint-Nazaire with four French-speaking speci-

alists will be actively entering the market in the western region of France

with demos sales and service for welding robots and the sale of welding

accessories The welding accessories of Valk Welding are kept in Saint-Na-

zaire where a number of welding robot systems are permanently set up for

demonstrations of both Panasonic and Fanuc robots

Valk Welding has already been selling and installing welding robot systems in the north of France for a number of years Valk Welding has now delivered more than sixty welding robot systems to local French companies in that area as well as to international compa-nies including Bosal Thule CNH Dhollandia and Mecanorem Valk Welding is setting out to increase its sales of welding robot systems in France by working in close partnership with local specialists

The official opening was conducted by Remco H Valk (CEO Valk Welding Group) Michel Devos (sales manager Valk Welding France) and Olivier Moyon Romuald Thomegravere Etienne Menard part-ners Valk Welding France Atlantique

Valk mailing a publication of Valk Welding 9t

h ye

ar -

200

9 -

no 1

copy Valk Welding BV 2009Alle rights reserved

Also in this issue

Valk Welding France Atlantique opens in Western France

bull Replacement programme makes investment

in the latest welding robot technology an

attractive option 2

bull Options for Tawers welding robot for alumi-

nium further extended 2

bull Demo training and service for East European

market 3

bull Crucial parts safely stored in new depot 3

bull Bollegraaf switches with welding robot cell

to single-article production 4

bull Faymonville installs Panasonic manual

welding machines throughout organisation 5

bull Combined arcstud welding robot for VDL 5

bull Joskin raises productivity with latest welding

robot technology 6-7

bull Marko installs fourth generation welding

robot system 8

bull Fabrice Lefegravevre pivot between a French

client and the Valk Welding organisation 8

2

Replacement programme

Owing to the long life span of the Panasonic welding robots more than 400 hundred of them of the older generations AW and VR (until 1992) are still in operation That makes these welding robots 17 years or older The chance of sudden production downtime will increase because it is becoming more difficult to supply components for these robots

In close partnership with Panasonic Welding Systems Valk Welding has created a unique replacement programme for this purpose That makes it possible for clients to replace their old welding robots for a welding robot of the latest TAWERS generation under highly favourable conditions That will secure production continuity and these clients will be given an attractive option for taking advantage of the latest technology

Best in class welding robotsThe Panasonic TAWERS welding robots are the only systems in which the welding unit and the welding robot are integrated in a sin-gle control system That places these robots in the lsquobest of classrsquo welding robots for arc welding applications

bull High welding qualitybull High productivitybull Lower operating costsbull Fast acceleration and movement speeds (up

to 180 mmin)bull Easy to operate and programmebull Very strong controllercontrolsbull Welding data registration and monitoringbull Broad range of standard welding software

and functionalitiesbull Several welding processes (MIG MAG TIG)

with a single machinebull Collision detectionbull Unique wire feed systembull Offline programmingbull Working range from 1400 and 1800 mm oslashbull Flexibly extendible with standard compo-

nents

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With the integration of robot and welding machine in a single control system Panasonic has placed a unique arc welding robot on the market that raises the quality and speed of the welding process to a higher level in the form of the TAWERS New features include lsquoSpiral Weavingrsquo and lsquoSynchro Pulsrsquo with which Panasonic has sub-stantially broadened the use of these arc welding robots for the MIG welding of aluminium

Integrating the robot and the welding machine in a single control system makes it possible to speed up data processing by 250 That facilitates the development of new software functionalities which in turn makes it possible to increasingly extend the use of the Panasonic TAWERS arc welding

robots The TAWERS is available with a broad range of standard welding software and func-tionalities such as lsquoAutomatic Start Retryrsquo lsquoArc Start Liftrsquo lsquoArc End Liftrsquo and welding data registration lsquoSpiral Weavingrsquo and lsquoSynchro Pulsrsquo are the latest software functionalities

Spiral Weaving for thin walled aluminiumlsquoSpiral Weavingrsquo involves building up the weld step by step in order to avoid excessively an-nealing and deforming the material The weld is built up with alternating parameters The extremely fast data processing in the control makes it possible to change the parameter settings at high frequency when the welding machine makes circular movements

Welding various aluminium thicknessesAnother new function is what is known as lsquoSynchro Pulsersquo This software facilitates the synchronisation of an alternating weld parameter with a pendulum movement which makes it possible to effectively weld

aluminium of various thicknesses with the right heat application and annealing of both materials See also the video at wwwvalkweldingczvideosvideo_en_21html

Spir

al W

eavi

ngSy

nchr

o Pu

ls

Options for Tawers welding robot for aluminium further extended

makes investment in the latest welding robot technology an attractive option

Valk Welding with Panasonic Tawers at Schweissen und Schneiden

Aged welding robots make way for the latest

generation

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LK

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93

Owing to strong growth in the sale of welding consumables and compo-nents Valk Welding has outgrown its storage depot in Alblasserdam so a new depot was recently taken into use at a different location As well as offering more capacity and options for further expansion it was also possible to take a step towards the fire-pro-tected storage of crucial components such as printed circuit boards and other specific Panasonic welding robot components The delivery times for specific parts such as these are usually long Keeping them in stock makes it possible for Valk Welding to minimise downtime if clients are affected by breakdowns

Warehouse manager Ad Hempenius has therefore opted for a solution in the form of a paternoster system This system offers a very large storage capacity with limited floor space The components can be retrieved by article number and are presented at opera-ting height That makes it possible to collect the desired components quickly and ergo-nomically An added advantage is that the storage system can be closed after working hours so that all components are properly

protected against fire and damage Together with assistant Hans Verhoeff Ad Hempenius prepares dozens of orders for welding con-sumables for consignment every day at this depot As well as complete Speedglas welding masks and 3M safety products stocks are also kept here of cables torch components and all components for Wire Wizard wire feed systems The high turnaround speeds and the depot manning make it possible to consign most orders on the same day

Crucial parts safely stored in new depot

Following the opening of a new location by the Danish location of Valk Welding in October 2008 and the opening of Valk Welding France Atlantique this spring the Czech location has also moved into larger premises From its new location close to Ostrava Airport Valk Welding CZ sro will be serving the entire region in and around the Czech Repu-blic Poland and Slovakia with training demos training and service

At the new location Valk Welding CZ sro has comprehensive facilities that it can use to continue to extend its service As well as the pro-vision of basic training courses to existing and new robot customers Valk Welding CZ sro in Mosnov will also be providing demonstrations and test setups for robot applications Additionally a select range of welding consumables will be kept in stock for regional clients Since its foundation in mid-2004 Valk Welding CZ sro has sold more than a hundred Panasonic robot systems to East European companies engaged with trailer construction the car industry and general sup-pliers

Valk Welding has now installed more than 1650 robots in European countries and beyondWith its head office in the Netherlands and independent locations in the Czech Republic Denmark Belgium and France Valk Welding is planning to grow as a European system integrator and sales organisa-tion for welding consumables

Demo training and service for East European

marketBased at new facility for Valk

Welding Czech Republic

Options for Tawers welding robot for aluminium further extended

Valk Welding with Panasonic Tawers at Schweissen und Schneiden

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4

Employing more than 650 people and with locations in Belgium France and Poland Joskin is currently one of Europersquos biggest agricultural vehicle producers The companyrsquos growth gained momentum as a result of a number of successful products for which Joskin produces all of the parts under its own management The company has trebled its turnover since opening production facilities in France and Poland

Initially tired of robotsIt will go without saying that a company of this size started using welding robots at an early stage But Joskin had never succeeded in achieving the desired result with them Pro-duction manager Didier Joskin explains the reasons for that ldquoThe operator was spending more time on programming and optimising the robots than on production We also had a lot of calibration problems and were unable to weld a number of products That led to serious delays in the cycle times and ultima-tely resulted in poor productivity levels Until recently we were pretty tired of robots We even considered switching to manual welding at our locations in Belgium and Polandrdquo

Valk Welding convincedWithout much hope in the summer of 2006 Joskin asked a number of suppliers to make

a proposal mainly aimed at achieving a rise in productivity and flexibility and improving the quality of the products for which welding robots were used Didier Joskin As a test object we gave them a hydraulic cylinder the product we have had the most trouble with Based on sound preparations Valk Welding delivered a perfect product and managed to put forward convincing arguments both on the technical front and at company level with its facilities in Alblasserdam It also became clear that the two companies had more in common than apparent at first glance a strong family firm character with enthusias-tic personnel a leading market position with a technically cutting edge product and strong growth combined with a healthy outlook

We decided to put the new Valk Welding system into operation as a pilot After that everything moved very quickly The quality was perfect the productivity rate was 25 to 50 higher we had no malfunctions and the setup time turned out to be many times shorter than what we were accustomed to That prompted our decision to replace all six existing welding robots with Panasonic TAWERS welding robotsrdquo

Hydraulic cylinders Joskin was experiencing the most problems

with the robotised welding of its hydraulic cylinders The success of this product was therefore an important factor in Joskinrsquos decision on whether to continue with robot welding Peter Pittomvils Valk Weldingrsquos technical consultant ldquoJoskin makes all of the hydraulic cylinders for its vehicles under its own management If you look at Joskinrsquos wide range of products that will give you an impression of the numbers That meant that robot welding would have benefits The main problem was found in welding the nipple on the cylinder The strong concentration of heat on a small area made it impossible to make the cylinder optimally round We managed to achieve that on the basis of our expertise and by using the new SP-MAG welding processrdquo

Standard systems for sub-assemblies Of the seven welding robots that Valk Welding has supplied to Joskin the first four are based on an H-frame concept with two clamping tables a manipulator and high speed doors Joskin used this relatively simple setup for welding small parts and sub-assem-blies To have a welding robot operate several clamping tables a fifth cell was fitted with a robot on a longitudinal travel This setup made it possible to achieve a long activation period for the welding robot The work pieces were clamped and taken out while the robot

Joskin which manufactures vehicles for manure spreading and agricultural transport systems has in recent years invested substantially in increasing its capacity and moder-nising its welding department Seven welding robot systems have now been put into operation at the production facility in Soumagne close to Luik and there are more to come Joskin has thus succeeded not only in sharply raising produc-tivity but also in achieving a higher and more consistent level of quality Joskin has opted for the latest welding robot technology of the Panasonic TAWERS welding robots and the DTPS G2 offline program-ming system

Detail of special jigs for welding hydraulic cylinders Didier Joskin

Joskin raises productivity with latest welding robot technology

5V

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00

9

Dominique Talmasse (r) robot programmer at Joskin and Peter Pittomvils sales manager Belgium of Valk Welding

Standard welding robot cell with two clamping tables and high speed door

3D simulation in DTPS G2 of the welding robot cell under construction that Joskin plans to use to weld complete dumper trucks

Joskin raises productivity with latest welding robot technology

was welding at another station A further two standard cells have recently been added Didier Joskin ldquoBy using seven cells wersquove succeeded in making more products with one less shift and have fully integrated all of the welding work This has also given us a guarantee of extra capacity in the futurerdquo

Latest generation of welding robotsFor the new welding robot cells Valk Welding has deployed the latest generation of Panasonicrsquos TAWERS welding robots With this robot which has been purpose built for arc welding the welding machine and the robot are integrated in a single control system The extremely high communication speeds that this achieves make the TAWERS the most advanced and fast welding robot on the market Didier Joskin ldquoThe TAWERS welding robot is a typically advanced top quality Japanese product with a high level of reliability and which is easy to programme The welding current source is unique and facilitates many software functionalities including a spat-free welding process and integrated welding data registration The col-lision detector is especially important to us In the event of a collision the welding robot switches to softndashservo which makes the robot arm lsquopliantrsquo so that no damage can be caused to the torch or robot arm and does away with the need to recalibraterdquo

Offline programmingOffline programming contributes signi-ficantly to the productivity gains of the TAWERS welding robots Valk Welding has been successfully using the programming

and simulation system DTPS G2 which it had a hand in developing for more than ten years That gives the robot operator control over the entire welding production process and also makes it possible for him to prepare welding programmes outside of production That not only yields a higher welding robot activation level but also facilitates a high level of flexibility For that reason it is no longer the size of the series that determi-nes whether profitable use can be made of welding robots

Total solution partnerJoskin was aware that outstanding quality and a fault-free supply of welding wire were vital to achieving maximum output That is why Joskin performed tests - free of obligation - with Valk Weldingrsquos solid welding wire in Ecodrums Much to Joskinrsquos surprise as well as the spat-free end result the wire feed with this welding wire was entirely faultless The price and production benefits were reason enough for Joskin to switch all of its robots to Valk Weldingrsquos welding wire Also with Valk Welding as a ldquoTotal Solution Partnerrdquo Joskin only has to deal with a single point of contact As well as the welding wire Panasonic welding machines and the com-pany consumables have now been put into operation too

Complete welding of dumper trucksNow that Joskin has acquired a taste for ro-bot welding it has moved on to the welding of larger work pieces Joskin will be welding complete tipping units for its dumper trucks using the next welding cell which has now

been put together at Valk Welding in Alblas-serdam Didier Joskin ldquoThe technology is al-ready there as are the internal logistics The problem is building the right jigs With this new welding robot cell we plan to welding 6 dumper trucks a day in 15 shiftsrdquo

Credit crisis presents new opportunitiesBy using the new welding robot cells Joskin has succeeded in substantially increasing productivity without employing extra people Didier Joskin ldquoWhich is just as well as those extra people are difficult to find in our re-gion The high production rates have made it possible for us to reduce delivery times The reduced number of orders caused by the cre-dit crisis is creating more gaps in production and in the organisation At last we now have time to turn our attention to new markets We currently have a presence with our products in more than 30 countries and we are extending our network to Eastern Europe We are also increasing our marketing efforts to strengthen our position in the countries in which we already operaterdquo

Continued investment in welding robot technologyDidier Joskin ldquoOur outlook is good despite the somewhat weaker economic conditions We plan to continue to invest in welding robots in order to keep pace with the anti-cipated growth in turnover We will soon be delivering our 24000th tank and the 7000th dumper truckwwwjoskincom

Robot programmer Dominique Talmasse working on the welding program for welding complete dumper trucks in DTPS G2

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The huge welding robot system that Valk Welding has built for Bollegraaf Recycling Machinery in Appingedam forms part of a sizeable investment programme intended to double the production of bale presses within 2 years Bollegraaf is thus anticipating strong growth in the market for envi-ronmental and recycling technology As well as the welding robot system the DTPS G2 offline programme sy-stem and Valk Weldingrsquos Wire Wizard wire feed system the investment programme also covers a cutting line and a heavy-duty bending robot That will make it possible for the company to sharply reduce its lead times and to flexibly produce single articles

The welding robot system has a longitudinal movement of 33 metres with three trans-verse movements of 3 metres combined with a height movement of 19 metres The three Panasonic TA1900-WG welding robots are suspended on the height movement The work pieces are positioned by 2 manipulators with bearing capacities of 6 and 25 tonsOn the heaviest manipulator complete bale press frames are simultaneously welded by 2 robots The stamps and large valves for the compression section of the Bollegraaf bale presses are made at the second clamping area All three robots can work at the same time and the manipulators can even be stee-red individually That means that a total of 27 shafts can be steered separately

MasterpieceWith the 27 individually steered shafts this project makes full use of the functionalities of the offline programme system DTPS G2 The safety zones are of great importance because the three welding robots must not get in each otherrsquos way For the head of production Bram Bos offline programming was one of the most important preconditi-ons ldquoWe wanted to weld complete frames and also to be able to programme them entirely offline With that aim in mind our preparations included taking a close look at

various shipbuilding and trailer construction projects throughout Europe Valk Welding was the only robot integrator that had previously delivered such a heavy system including one to the Polish trailer building Wielton The decisive factor was the fact that Valk Welding is an organisation with high level technical knowledge of both robotics and weldingrdquo

Action planldquoGetting a project such as this off the ground is by no means an everyday event either for the supplier or for us Implementing a system like this involves a completely different working method which has to be supported by all departments Also it was necessary to create the right mindset for programming for single article production For that reason we created a large project team comprising 6 people from Bollegraaf and 5 from Valk Welding That means that RampD engineering and production people were closely involved in the completion of this project At the same time a number of employees were trained in programmingrdquo explains Bram Bos

Sharp reduction in lead timesAs well as the benefits of a high repetition precision business-economic considerations were of great importance to Bollegraafrsquos decision to give this automation operation

the green light Bollegraafrsquos welders needed a total of 2 weeks (including finishing) to manually weld frames for the bale presses with 3 layer angle welds The deployment of 2 welding robots reduced the cycle time for a complete frame to 21 hours Not only has that given Bollegraaf a substantial saving on wage costs the shorter lead times mean that it is no longer necessary to produce stock parts That fully meets the objective of raising flexibility and reducing stocks to zero

Thick plate softwareThe frames for Bollegraafrsquos bale presses are built up with 30mm steel plate Most of the welding is carried out with angle welds in three layers with 12 mm solid SG2 wire in A15 welding height The use of Thick Plate software makes it possible to automatically build up all layers with a robot program that only traces the first layer and fast access ma-cros are used to quickly and easily ascertain the tolerance in the product

Bollegraaf Recycling Machinery manufactures products including bale presses for waste paper and systems for processing industrial and domestic wastewwwbollegraafcom

Bollegraaf switches with welding robot cell to single-article production

VA

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The company Faymonville the Bene-lux regionrsquos biggest manufacturer of semi-trailers for special transport has equipped all of its production units with Panasonic manual welding power sources Valk Welding has supplied the company with 250 manual welding machines over the past two years Faymonville uses these manual wel-ding power sources to completely weld heavy structural sections with lengths up to 18 metres The manual welding stations at Faymonville are also equip-ped with Wire Wizard welding wire feed systems in order to smoothly bridge the distance between the wel-

ding power source and the wire drive unit which in some cases exceeds a length of 12 metres

Faymonville has entered into a service contract with Valk Welding under which a unit price per year is paid for service and maintenance and the replacement of com-ponents This service contract has been taken out for a 10-year period after which it can be renewed for 2-year periods for each welding power source This service contract makes it possible for Faymonville to schedule the maintenance and overhaul costs for all of the organisationrsquos welding equipment Faymon-ville employs some 640 people Faymonville is now also using 4 welding robot systems wwwfaymonvillecom

Faymonville installs Panasonic manual welding machines throughout organisation

Valk Welding has recently supplied a combined arcstud welding system to the VDL Group The system is used to weld products for the car indus-try Products for this sector must be delivered absolutely free of defects The attachment of components using the stud welding method therefore has to be carried out fully automatically at all times To be completely certain that these studs have actually been attached the studs are welded onto the product by the robot

To have the arc welding and the stud welding carried out fully automatically with a single

robot the Panasonic arc welding robot is equipped with a Schunk tool changer That makes it possible for the robot to alternative fully automatically between the standard arc welding torch and the stud welding torch of Thomas Welding The stud welding head is equipped with a fully automatic feed that po-sitions the studs in the head The application of this special combination is the result of years of successful partnership between the VDL Group and Valk Welding and has led to a high degree of automation in several welding processes This system is the seventh arc welding robot that Valk Welding has installed within the VDL Group

See the video at wwwvalkweldingczvideosvideo_en_6html

Combined arcstud welding robot for VDL

Bollegraaf Recycling Machinery manufactu-res products including bale presses for waste paper and systems for processing industrial and domestic waste

Colophon

lsquoValk Mailingrsquo is a twice-yearly publication of Valk Welding BV and is sent free to all business relations If you want to receive this publication

in the future please send an email to infovalkweldingcom

The NetherlandsValk Welding BV

Staalindustrieweg 15PO Box 60

2950 AB AlblasserdamTel +31 78 69 170 11Fax +31 78 69 195 15

infovalkweldingcomwwwvalkweldingcom

BelgiumTel +32 (0)3 685 14 77Fax +32 (0)3 685 12 33

France Valk Welding France

Tel +33 (0)3 20 10 00 39Fax +33 (0)3 20 10 01 12

DenmarkValk Welding DK AS Tel +45 64421201Fax +45 64421202

Czech RepublicValk Welding CZ sro

Tel +420 556 73 0954Fax +420 556 73 1680

ProductionSteenkist Communicatie NL-Haarlem

steencomtiscalinl

PhotographyValk Welding BV

Erik Steenkist Marko bv Bollegraaf

Trade Fairs and Events

Vision amp Robotics Nieuwegein The Netherlands

16-17 June 2009

Schweissen und Schneiden Essen Germany

14-19 September 2009

Eurowelding ndash MSV 2009 Brno Czech Republic

14-18 September 2009

Metavak Gorinchem The Netherlands

10-12 November 2009

-

Marko installs fourth genera-tion welding robot system In spring of this year furniture produ-cer Marko BV put a new advanced welding robot system into operation at its production facility in Veendam The welding robot system represents the companyrsquos fourth generation of welding robots Marko was leading the way in the robotised welding of steel office and school furniture as far back as in the nineteen-eighties The investment in a Panasonic Tawers welding robot on a longitudinal movement and with 8 work stations has provided Marko with the last word in welding robot technology Marko is thus setting out to guaran-tee its product quality and production efficiency in the years to come

Higher capacity utilisation levelThe ample number of work stations makes it possible to limit the number of tool changes which leads to increased in productivity and flexibility That has increased the capacity utilisation level compared to the previous system The DTPS G2 offline programming system makes it possible to convert the programs of the older robots for the new robot system Also new products can be programmed offline and are easy to transfer or copy to other work stationsMarko achieves 80 of its turnover with school furniture and sets out to compete with its products mainly on quality With this strategy the company has succeeded in gaining a leading market position in the Benelux region wwwmarkoinfo

To overcome language barriers between French-speaking clients and the Dutch Valk Welding organi-sation telephone calls from France are first put directly through to our French-speaking office worker Fabrice Lefegravevre The need to communicate in French with the Dutch head office of Valk Welding had come about owing to the growth in the number of Fre-nch-speaking clients and the exten-sion of the sales activities caused by the incorporation of Valk Welding France Atlantique

Fabrice Lefegravevre is a Frenchman who has lived for more than 25 years in the Netherlands and has worked at Valk Welding in Alblasserdam since February of this

year Fabrice has a technical background in the bodywork sector and has broad know-ledge of welding technology which ideally places him to give clients an optimum service for both technical and administra-tive issues He thus forms the pivot between French-speaking clients and the Dutch Valk Welding organisation and supports the field service staff of Valk Welding France and Valk Welding France Atlantique

Fabrice Lefegravevre pivot between French clients and the Valk Welding organisation

Video ArchiveWant to see how it works Watch the videos of current robot projects atwwwvalkweldingczvideos

Page 2: 2009-01-Valk Mailing-EN

2

Replacement programme

Owing to the long life span of the Panasonic welding robots more than 400 hundred of them of the older generations AW and VR (until 1992) are still in operation That makes these welding robots 17 years or older The chance of sudden production downtime will increase because it is becoming more difficult to supply components for these robots

In close partnership with Panasonic Welding Systems Valk Welding has created a unique replacement programme for this purpose That makes it possible for clients to replace their old welding robots for a welding robot of the latest TAWERS generation under highly favourable conditions That will secure production continuity and these clients will be given an attractive option for taking advantage of the latest technology

Best in class welding robotsThe Panasonic TAWERS welding robots are the only systems in which the welding unit and the welding robot are integrated in a sin-gle control system That places these robots in the lsquobest of classrsquo welding robots for arc welding applications

bull High welding qualitybull High productivitybull Lower operating costsbull Fast acceleration and movement speeds (up

to 180 mmin)bull Easy to operate and programmebull Very strong controllercontrolsbull Welding data registration and monitoringbull Broad range of standard welding software

and functionalitiesbull Several welding processes (MIG MAG TIG)

with a single machinebull Collision detectionbull Unique wire feed systembull Offline programmingbull Working range from 1400 and 1800 mm oslashbull Flexibly extendible with standard compo-

nents

VA

LK

MA

ILIN

G

20

09

With the integration of robot and welding machine in a single control system Panasonic has placed a unique arc welding robot on the market that raises the quality and speed of the welding process to a higher level in the form of the TAWERS New features include lsquoSpiral Weavingrsquo and lsquoSynchro Pulsrsquo with which Panasonic has sub-stantially broadened the use of these arc welding robots for the MIG welding of aluminium

Integrating the robot and the welding machine in a single control system makes it possible to speed up data processing by 250 That facilitates the development of new software functionalities which in turn makes it possible to increasingly extend the use of the Panasonic TAWERS arc welding

robots The TAWERS is available with a broad range of standard welding software and func-tionalities such as lsquoAutomatic Start Retryrsquo lsquoArc Start Liftrsquo lsquoArc End Liftrsquo and welding data registration lsquoSpiral Weavingrsquo and lsquoSynchro Pulsrsquo are the latest software functionalities

Spiral Weaving for thin walled aluminiumlsquoSpiral Weavingrsquo involves building up the weld step by step in order to avoid excessively an-nealing and deforming the material The weld is built up with alternating parameters The extremely fast data processing in the control makes it possible to change the parameter settings at high frequency when the welding machine makes circular movements

Welding various aluminium thicknessesAnother new function is what is known as lsquoSynchro Pulsersquo This software facilitates the synchronisation of an alternating weld parameter with a pendulum movement which makes it possible to effectively weld

aluminium of various thicknesses with the right heat application and annealing of both materials See also the video at wwwvalkweldingczvideosvideo_en_21html

Spir

al W

eavi

ngSy

nchr

o Pu

ls

Options for Tawers welding robot for aluminium further extended

makes investment in the latest welding robot technology an attractive option

Valk Welding with Panasonic Tawers at Schweissen und Schneiden

Aged welding robots make way for the latest

generation

VA

LK

MA

ILIN

G

2

00

93

Owing to strong growth in the sale of welding consumables and compo-nents Valk Welding has outgrown its storage depot in Alblasserdam so a new depot was recently taken into use at a different location As well as offering more capacity and options for further expansion it was also possible to take a step towards the fire-pro-tected storage of crucial components such as printed circuit boards and other specific Panasonic welding robot components The delivery times for specific parts such as these are usually long Keeping them in stock makes it possible for Valk Welding to minimise downtime if clients are affected by breakdowns

Warehouse manager Ad Hempenius has therefore opted for a solution in the form of a paternoster system This system offers a very large storage capacity with limited floor space The components can be retrieved by article number and are presented at opera-ting height That makes it possible to collect the desired components quickly and ergo-nomically An added advantage is that the storage system can be closed after working hours so that all components are properly

protected against fire and damage Together with assistant Hans Verhoeff Ad Hempenius prepares dozens of orders for welding con-sumables for consignment every day at this depot As well as complete Speedglas welding masks and 3M safety products stocks are also kept here of cables torch components and all components for Wire Wizard wire feed systems The high turnaround speeds and the depot manning make it possible to consign most orders on the same day

Crucial parts safely stored in new depot

Following the opening of a new location by the Danish location of Valk Welding in October 2008 and the opening of Valk Welding France Atlantique this spring the Czech location has also moved into larger premises From its new location close to Ostrava Airport Valk Welding CZ sro will be serving the entire region in and around the Czech Repu-blic Poland and Slovakia with training demos training and service

At the new location Valk Welding CZ sro has comprehensive facilities that it can use to continue to extend its service As well as the pro-vision of basic training courses to existing and new robot customers Valk Welding CZ sro in Mosnov will also be providing demonstrations and test setups for robot applications Additionally a select range of welding consumables will be kept in stock for regional clients Since its foundation in mid-2004 Valk Welding CZ sro has sold more than a hundred Panasonic robot systems to East European companies engaged with trailer construction the car industry and general sup-pliers

Valk Welding has now installed more than 1650 robots in European countries and beyondWith its head office in the Netherlands and independent locations in the Czech Republic Denmark Belgium and France Valk Welding is planning to grow as a European system integrator and sales organisa-tion for welding consumables

Demo training and service for East European

marketBased at new facility for Valk

Welding Czech Republic

Options for Tawers welding robot for aluminium further extended

Valk Welding with Panasonic Tawers at Schweissen und Schneiden

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Employing more than 650 people and with locations in Belgium France and Poland Joskin is currently one of Europersquos biggest agricultural vehicle producers The companyrsquos growth gained momentum as a result of a number of successful products for which Joskin produces all of the parts under its own management The company has trebled its turnover since opening production facilities in France and Poland

Initially tired of robotsIt will go without saying that a company of this size started using welding robots at an early stage But Joskin had never succeeded in achieving the desired result with them Pro-duction manager Didier Joskin explains the reasons for that ldquoThe operator was spending more time on programming and optimising the robots than on production We also had a lot of calibration problems and were unable to weld a number of products That led to serious delays in the cycle times and ultima-tely resulted in poor productivity levels Until recently we were pretty tired of robots We even considered switching to manual welding at our locations in Belgium and Polandrdquo

Valk Welding convincedWithout much hope in the summer of 2006 Joskin asked a number of suppliers to make

a proposal mainly aimed at achieving a rise in productivity and flexibility and improving the quality of the products for which welding robots were used Didier Joskin As a test object we gave them a hydraulic cylinder the product we have had the most trouble with Based on sound preparations Valk Welding delivered a perfect product and managed to put forward convincing arguments both on the technical front and at company level with its facilities in Alblasserdam It also became clear that the two companies had more in common than apparent at first glance a strong family firm character with enthusias-tic personnel a leading market position with a technically cutting edge product and strong growth combined with a healthy outlook

We decided to put the new Valk Welding system into operation as a pilot After that everything moved very quickly The quality was perfect the productivity rate was 25 to 50 higher we had no malfunctions and the setup time turned out to be many times shorter than what we were accustomed to That prompted our decision to replace all six existing welding robots with Panasonic TAWERS welding robotsrdquo

Hydraulic cylinders Joskin was experiencing the most problems

with the robotised welding of its hydraulic cylinders The success of this product was therefore an important factor in Joskinrsquos decision on whether to continue with robot welding Peter Pittomvils Valk Weldingrsquos technical consultant ldquoJoskin makes all of the hydraulic cylinders for its vehicles under its own management If you look at Joskinrsquos wide range of products that will give you an impression of the numbers That meant that robot welding would have benefits The main problem was found in welding the nipple on the cylinder The strong concentration of heat on a small area made it impossible to make the cylinder optimally round We managed to achieve that on the basis of our expertise and by using the new SP-MAG welding processrdquo

Standard systems for sub-assemblies Of the seven welding robots that Valk Welding has supplied to Joskin the first four are based on an H-frame concept with two clamping tables a manipulator and high speed doors Joskin used this relatively simple setup for welding small parts and sub-assem-blies To have a welding robot operate several clamping tables a fifth cell was fitted with a robot on a longitudinal travel This setup made it possible to achieve a long activation period for the welding robot The work pieces were clamped and taken out while the robot

Joskin which manufactures vehicles for manure spreading and agricultural transport systems has in recent years invested substantially in increasing its capacity and moder-nising its welding department Seven welding robot systems have now been put into operation at the production facility in Soumagne close to Luik and there are more to come Joskin has thus succeeded not only in sharply raising produc-tivity but also in achieving a higher and more consistent level of quality Joskin has opted for the latest welding robot technology of the Panasonic TAWERS welding robots and the DTPS G2 offline program-ming system

Detail of special jigs for welding hydraulic cylinders Didier Joskin

Joskin raises productivity with latest welding robot technology

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Dominique Talmasse (r) robot programmer at Joskin and Peter Pittomvils sales manager Belgium of Valk Welding

Standard welding robot cell with two clamping tables and high speed door

3D simulation in DTPS G2 of the welding robot cell under construction that Joskin plans to use to weld complete dumper trucks

Joskin raises productivity with latest welding robot technology

was welding at another station A further two standard cells have recently been added Didier Joskin ldquoBy using seven cells wersquove succeeded in making more products with one less shift and have fully integrated all of the welding work This has also given us a guarantee of extra capacity in the futurerdquo

Latest generation of welding robotsFor the new welding robot cells Valk Welding has deployed the latest generation of Panasonicrsquos TAWERS welding robots With this robot which has been purpose built for arc welding the welding machine and the robot are integrated in a single control system The extremely high communication speeds that this achieves make the TAWERS the most advanced and fast welding robot on the market Didier Joskin ldquoThe TAWERS welding robot is a typically advanced top quality Japanese product with a high level of reliability and which is easy to programme The welding current source is unique and facilitates many software functionalities including a spat-free welding process and integrated welding data registration The col-lision detector is especially important to us In the event of a collision the welding robot switches to softndashservo which makes the robot arm lsquopliantrsquo so that no damage can be caused to the torch or robot arm and does away with the need to recalibraterdquo

Offline programmingOffline programming contributes signi-ficantly to the productivity gains of the TAWERS welding robots Valk Welding has been successfully using the programming

and simulation system DTPS G2 which it had a hand in developing for more than ten years That gives the robot operator control over the entire welding production process and also makes it possible for him to prepare welding programmes outside of production That not only yields a higher welding robot activation level but also facilitates a high level of flexibility For that reason it is no longer the size of the series that determi-nes whether profitable use can be made of welding robots

Total solution partnerJoskin was aware that outstanding quality and a fault-free supply of welding wire were vital to achieving maximum output That is why Joskin performed tests - free of obligation - with Valk Weldingrsquos solid welding wire in Ecodrums Much to Joskinrsquos surprise as well as the spat-free end result the wire feed with this welding wire was entirely faultless The price and production benefits were reason enough for Joskin to switch all of its robots to Valk Weldingrsquos welding wire Also with Valk Welding as a ldquoTotal Solution Partnerrdquo Joskin only has to deal with a single point of contact As well as the welding wire Panasonic welding machines and the com-pany consumables have now been put into operation too

Complete welding of dumper trucksNow that Joskin has acquired a taste for ro-bot welding it has moved on to the welding of larger work pieces Joskin will be welding complete tipping units for its dumper trucks using the next welding cell which has now

been put together at Valk Welding in Alblas-serdam Didier Joskin ldquoThe technology is al-ready there as are the internal logistics The problem is building the right jigs With this new welding robot cell we plan to welding 6 dumper trucks a day in 15 shiftsrdquo

Credit crisis presents new opportunitiesBy using the new welding robot cells Joskin has succeeded in substantially increasing productivity without employing extra people Didier Joskin ldquoWhich is just as well as those extra people are difficult to find in our re-gion The high production rates have made it possible for us to reduce delivery times The reduced number of orders caused by the cre-dit crisis is creating more gaps in production and in the organisation At last we now have time to turn our attention to new markets We currently have a presence with our products in more than 30 countries and we are extending our network to Eastern Europe We are also increasing our marketing efforts to strengthen our position in the countries in which we already operaterdquo

Continued investment in welding robot technologyDidier Joskin ldquoOur outlook is good despite the somewhat weaker economic conditions We plan to continue to invest in welding robots in order to keep pace with the anti-cipated growth in turnover We will soon be delivering our 24000th tank and the 7000th dumper truckwwwjoskincom

Robot programmer Dominique Talmasse working on the welding program for welding complete dumper trucks in DTPS G2

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The huge welding robot system that Valk Welding has built for Bollegraaf Recycling Machinery in Appingedam forms part of a sizeable investment programme intended to double the production of bale presses within 2 years Bollegraaf is thus anticipating strong growth in the market for envi-ronmental and recycling technology As well as the welding robot system the DTPS G2 offline programme sy-stem and Valk Weldingrsquos Wire Wizard wire feed system the investment programme also covers a cutting line and a heavy-duty bending robot That will make it possible for the company to sharply reduce its lead times and to flexibly produce single articles

The welding robot system has a longitudinal movement of 33 metres with three trans-verse movements of 3 metres combined with a height movement of 19 metres The three Panasonic TA1900-WG welding robots are suspended on the height movement The work pieces are positioned by 2 manipulators with bearing capacities of 6 and 25 tonsOn the heaviest manipulator complete bale press frames are simultaneously welded by 2 robots The stamps and large valves for the compression section of the Bollegraaf bale presses are made at the second clamping area All three robots can work at the same time and the manipulators can even be stee-red individually That means that a total of 27 shafts can be steered separately

MasterpieceWith the 27 individually steered shafts this project makes full use of the functionalities of the offline programme system DTPS G2 The safety zones are of great importance because the three welding robots must not get in each otherrsquos way For the head of production Bram Bos offline programming was one of the most important preconditi-ons ldquoWe wanted to weld complete frames and also to be able to programme them entirely offline With that aim in mind our preparations included taking a close look at

various shipbuilding and trailer construction projects throughout Europe Valk Welding was the only robot integrator that had previously delivered such a heavy system including one to the Polish trailer building Wielton The decisive factor was the fact that Valk Welding is an organisation with high level technical knowledge of both robotics and weldingrdquo

Action planldquoGetting a project such as this off the ground is by no means an everyday event either for the supplier or for us Implementing a system like this involves a completely different working method which has to be supported by all departments Also it was necessary to create the right mindset for programming for single article production For that reason we created a large project team comprising 6 people from Bollegraaf and 5 from Valk Welding That means that RampD engineering and production people were closely involved in the completion of this project At the same time a number of employees were trained in programmingrdquo explains Bram Bos

Sharp reduction in lead timesAs well as the benefits of a high repetition precision business-economic considerations were of great importance to Bollegraafrsquos decision to give this automation operation

the green light Bollegraafrsquos welders needed a total of 2 weeks (including finishing) to manually weld frames for the bale presses with 3 layer angle welds The deployment of 2 welding robots reduced the cycle time for a complete frame to 21 hours Not only has that given Bollegraaf a substantial saving on wage costs the shorter lead times mean that it is no longer necessary to produce stock parts That fully meets the objective of raising flexibility and reducing stocks to zero

Thick plate softwareThe frames for Bollegraafrsquos bale presses are built up with 30mm steel plate Most of the welding is carried out with angle welds in three layers with 12 mm solid SG2 wire in A15 welding height The use of Thick Plate software makes it possible to automatically build up all layers with a robot program that only traces the first layer and fast access ma-cros are used to quickly and easily ascertain the tolerance in the product

Bollegraaf Recycling Machinery manufactures products including bale presses for waste paper and systems for processing industrial and domestic wastewwwbollegraafcom

Bollegraaf switches with welding robot cell to single-article production

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The company Faymonville the Bene-lux regionrsquos biggest manufacturer of semi-trailers for special transport has equipped all of its production units with Panasonic manual welding power sources Valk Welding has supplied the company with 250 manual welding machines over the past two years Faymonville uses these manual wel-ding power sources to completely weld heavy structural sections with lengths up to 18 metres The manual welding stations at Faymonville are also equip-ped with Wire Wizard welding wire feed systems in order to smoothly bridge the distance between the wel-

ding power source and the wire drive unit which in some cases exceeds a length of 12 metres

Faymonville has entered into a service contract with Valk Welding under which a unit price per year is paid for service and maintenance and the replacement of com-ponents This service contract has been taken out for a 10-year period after which it can be renewed for 2-year periods for each welding power source This service contract makes it possible for Faymonville to schedule the maintenance and overhaul costs for all of the organisationrsquos welding equipment Faymon-ville employs some 640 people Faymonville is now also using 4 welding robot systems wwwfaymonvillecom

Faymonville installs Panasonic manual welding machines throughout organisation

Valk Welding has recently supplied a combined arcstud welding system to the VDL Group The system is used to weld products for the car indus-try Products for this sector must be delivered absolutely free of defects The attachment of components using the stud welding method therefore has to be carried out fully automatically at all times To be completely certain that these studs have actually been attached the studs are welded onto the product by the robot

To have the arc welding and the stud welding carried out fully automatically with a single

robot the Panasonic arc welding robot is equipped with a Schunk tool changer That makes it possible for the robot to alternative fully automatically between the standard arc welding torch and the stud welding torch of Thomas Welding The stud welding head is equipped with a fully automatic feed that po-sitions the studs in the head The application of this special combination is the result of years of successful partnership between the VDL Group and Valk Welding and has led to a high degree of automation in several welding processes This system is the seventh arc welding robot that Valk Welding has installed within the VDL Group

See the video at wwwvalkweldingczvideosvideo_en_6html

Combined arcstud welding robot for VDL

Bollegraaf Recycling Machinery manufactu-res products including bale presses for waste paper and systems for processing industrial and domestic waste

Colophon

lsquoValk Mailingrsquo is a twice-yearly publication of Valk Welding BV and is sent free to all business relations If you want to receive this publication

in the future please send an email to infovalkweldingcom

The NetherlandsValk Welding BV

Staalindustrieweg 15PO Box 60

2950 AB AlblasserdamTel +31 78 69 170 11Fax +31 78 69 195 15

infovalkweldingcomwwwvalkweldingcom

BelgiumTel +32 (0)3 685 14 77Fax +32 (0)3 685 12 33

France Valk Welding France

Tel +33 (0)3 20 10 00 39Fax +33 (0)3 20 10 01 12

DenmarkValk Welding DK AS Tel +45 64421201Fax +45 64421202

Czech RepublicValk Welding CZ sro

Tel +420 556 73 0954Fax +420 556 73 1680

ProductionSteenkist Communicatie NL-Haarlem

steencomtiscalinl

PhotographyValk Welding BV

Erik Steenkist Marko bv Bollegraaf

Trade Fairs and Events

Vision amp Robotics Nieuwegein The Netherlands

16-17 June 2009

Schweissen und Schneiden Essen Germany

14-19 September 2009

Eurowelding ndash MSV 2009 Brno Czech Republic

14-18 September 2009

Metavak Gorinchem The Netherlands

10-12 November 2009

-

Marko installs fourth genera-tion welding robot system In spring of this year furniture produ-cer Marko BV put a new advanced welding robot system into operation at its production facility in Veendam The welding robot system represents the companyrsquos fourth generation of welding robots Marko was leading the way in the robotised welding of steel office and school furniture as far back as in the nineteen-eighties The investment in a Panasonic Tawers welding robot on a longitudinal movement and with 8 work stations has provided Marko with the last word in welding robot technology Marko is thus setting out to guaran-tee its product quality and production efficiency in the years to come

Higher capacity utilisation levelThe ample number of work stations makes it possible to limit the number of tool changes which leads to increased in productivity and flexibility That has increased the capacity utilisation level compared to the previous system The DTPS G2 offline programming system makes it possible to convert the programs of the older robots for the new robot system Also new products can be programmed offline and are easy to transfer or copy to other work stationsMarko achieves 80 of its turnover with school furniture and sets out to compete with its products mainly on quality With this strategy the company has succeeded in gaining a leading market position in the Benelux region wwwmarkoinfo

To overcome language barriers between French-speaking clients and the Dutch Valk Welding organi-sation telephone calls from France are first put directly through to our French-speaking office worker Fabrice Lefegravevre The need to communicate in French with the Dutch head office of Valk Welding had come about owing to the growth in the number of Fre-nch-speaking clients and the exten-sion of the sales activities caused by the incorporation of Valk Welding France Atlantique

Fabrice Lefegravevre is a Frenchman who has lived for more than 25 years in the Netherlands and has worked at Valk Welding in Alblasserdam since February of this

year Fabrice has a technical background in the bodywork sector and has broad know-ledge of welding technology which ideally places him to give clients an optimum service for both technical and administra-tive issues He thus forms the pivot between French-speaking clients and the Dutch Valk Welding organisation and supports the field service staff of Valk Welding France and Valk Welding France Atlantique

Fabrice Lefegravevre pivot between French clients and the Valk Welding organisation

Video ArchiveWant to see how it works Watch the videos of current robot projects atwwwvalkweldingczvideos

Page 3: 2009-01-Valk Mailing-EN

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Owing to strong growth in the sale of welding consumables and compo-nents Valk Welding has outgrown its storage depot in Alblasserdam so a new depot was recently taken into use at a different location As well as offering more capacity and options for further expansion it was also possible to take a step towards the fire-pro-tected storage of crucial components such as printed circuit boards and other specific Panasonic welding robot components The delivery times for specific parts such as these are usually long Keeping them in stock makes it possible for Valk Welding to minimise downtime if clients are affected by breakdowns

Warehouse manager Ad Hempenius has therefore opted for a solution in the form of a paternoster system This system offers a very large storage capacity with limited floor space The components can be retrieved by article number and are presented at opera-ting height That makes it possible to collect the desired components quickly and ergo-nomically An added advantage is that the storage system can be closed after working hours so that all components are properly

protected against fire and damage Together with assistant Hans Verhoeff Ad Hempenius prepares dozens of orders for welding con-sumables for consignment every day at this depot As well as complete Speedglas welding masks and 3M safety products stocks are also kept here of cables torch components and all components for Wire Wizard wire feed systems The high turnaround speeds and the depot manning make it possible to consign most orders on the same day

Crucial parts safely stored in new depot

Following the opening of a new location by the Danish location of Valk Welding in October 2008 and the opening of Valk Welding France Atlantique this spring the Czech location has also moved into larger premises From its new location close to Ostrava Airport Valk Welding CZ sro will be serving the entire region in and around the Czech Repu-blic Poland and Slovakia with training demos training and service

At the new location Valk Welding CZ sro has comprehensive facilities that it can use to continue to extend its service As well as the pro-vision of basic training courses to existing and new robot customers Valk Welding CZ sro in Mosnov will also be providing demonstrations and test setups for robot applications Additionally a select range of welding consumables will be kept in stock for regional clients Since its foundation in mid-2004 Valk Welding CZ sro has sold more than a hundred Panasonic robot systems to East European companies engaged with trailer construction the car industry and general sup-pliers

Valk Welding has now installed more than 1650 robots in European countries and beyondWith its head office in the Netherlands and independent locations in the Czech Republic Denmark Belgium and France Valk Welding is planning to grow as a European system integrator and sales organisa-tion for welding consumables

Demo training and service for East European

marketBased at new facility for Valk

Welding Czech Republic

Options for Tawers welding robot for aluminium further extended

Valk Welding with Panasonic Tawers at Schweissen und Schneiden

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Employing more than 650 people and with locations in Belgium France and Poland Joskin is currently one of Europersquos biggest agricultural vehicle producers The companyrsquos growth gained momentum as a result of a number of successful products for which Joskin produces all of the parts under its own management The company has trebled its turnover since opening production facilities in France and Poland

Initially tired of robotsIt will go without saying that a company of this size started using welding robots at an early stage But Joskin had never succeeded in achieving the desired result with them Pro-duction manager Didier Joskin explains the reasons for that ldquoThe operator was spending more time on programming and optimising the robots than on production We also had a lot of calibration problems and were unable to weld a number of products That led to serious delays in the cycle times and ultima-tely resulted in poor productivity levels Until recently we were pretty tired of robots We even considered switching to manual welding at our locations in Belgium and Polandrdquo

Valk Welding convincedWithout much hope in the summer of 2006 Joskin asked a number of suppliers to make

a proposal mainly aimed at achieving a rise in productivity and flexibility and improving the quality of the products for which welding robots were used Didier Joskin As a test object we gave them a hydraulic cylinder the product we have had the most trouble with Based on sound preparations Valk Welding delivered a perfect product and managed to put forward convincing arguments both on the technical front and at company level with its facilities in Alblasserdam It also became clear that the two companies had more in common than apparent at first glance a strong family firm character with enthusias-tic personnel a leading market position with a technically cutting edge product and strong growth combined with a healthy outlook

We decided to put the new Valk Welding system into operation as a pilot After that everything moved very quickly The quality was perfect the productivity rate was 25 to 50 higher we had no malfunctions and the setup time turned out to be many times shorter than what we were accustomed to That prompted our decision to replace all six existing welding robots with Panasonic TAWERS welding robotsrdquo

Hydraulic cylinders Joskin was experiencing the most problems

with the robotised welding of its hydraulic cylinders The success of this product was therefore an important factor in Joskinrsquos decision on whether to continue with robot welding Peter Pittomvils Valk Weldingrsquos technical consultant ldquoJoskin makes all of the hydraulic cylinders for its vehicles under its own management If you look at Joskinrsquos wide range of products that will give you an impression of the numbers That meant that robot welding would have benefits The main problem was found in welding the nipple on the cylinder The strong concentration of heat on a small area made it impossible to make the cylinder optimally round We managed to achieve that on the basis of our expertise and by using the new SP-MAG welding processrdquo

Standard systems for sub-assemblies Of the seven welding robots that Valk Welding has supplied to Joskin the first four are based on an H-frame concept with two clamping tables a manipulator and high speed doors Joskin used this relatively simple setup for welding small parts and sub-assem-blies To have a welding robot operate several clamping tables a fifth cell was fitted with a robot on a longitudinal travel This setup made it possible to achieve a long activation period for the welding robot The work pieces were clamped and taken out while the robot

Joskin which manufactures vehicles for manure spreading and agricultural transport systems has in recent years invested substantially in increasing its capacity and moder-nising its welding department Seven welding robot systems have now been put into operation at the production facility in Soumagne close to Luik and there are more to come Joskin has thus succeeded not only in sharply raising produc-tivity but also in achieving a higher and more consistent level of quality Joskin has opted for the latest welding robot technology of the Panasonic TAWERS welding robots and the DTPS G2 offline program-ming system

Detail of special jigs for welding hydraulic cylinders Didier Joskin

Joskin raises productivity with latest welding robot technology

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Dominique Talmasse (r) robot programmer at Joskin and Peter Pittomvils sales manager Belgium of Valk Welding

Standard welding robot cell with two clamping tables and high speed door

3D simulation in DTPS G2 of the welding robot cell under construction that Joskin plans to use to weld complete dumper trucks

Joskin raises productivity with latest welding robot technology

was welding at another station A further two standard cells have recently been added Didier Joskin ldquoBy using seven cells wersquove succeeded in making more products with one less shift and have fully integrated all of the welding work This has also given us a guarantee of extra capacity in the futurerdquo

Latest generation of welding robotsFor the new welding robot cells Valk Welding has deployed the latest generation of Panasonicrsquos TAWERS welding robots With this robot which has been purpose built for arc welding the welding machine and the robot are integrated in a single control system The extremely high communication speeds that this achieves make the TAWERS the most advanced and fast welding robot on the market Didier Joskin ldquoThe TAWERS welding robot is a typically advanced top quality Japanese product with a high level of reliability and which is easy to programme The welding current source is unique and facilitates many software functionalities including a spat-free welding process and integrated welding data registration The col-lision detector is especially important to us In the event of a collision the welding robot switches to softndashservo which makes the robot arm lsquopliantrsquo so that no damage can be caused to the torch or robot arm and does away with the need to recalibraterdquo

Offline programmingOffline programming contributes signi-ficantly to the productivity gains of the TAWERS welding robots Valk Welding has been successfully using the programming

and simulation system DTPS G2 which it had a hand in developing for more than ten years That gives the robot operator control over the entire welding production process and also makes it possible for him to prepare welding programmes outside of production That not only yields a higher welding robot activation level but also facilitates a high level of flexibility For that reason it is no longer the size of the series that determi-nes whether profitable use can be made of welding robots

Total solution partnerJoskin was aware that outstanding quality and a fault-free supply of welding wire were vital to achieving maximum output That is why Joskin performed tests - free of obligation - with Valk Weldingrsquos solid welding wire in Ecodrums Much to Joskinrsquos surprise as well as the spat-free end result the wire feed with this welding wire was entirely faultless The price and production benefits were reason enough for Joskin to switch all of its robots to Valk Weldingrsquos welding wire Also with Valk Welding as a ldquoTotal Solution Partnerrdquo Joskin only has to deal with a single point of contact As well as the welding wire Panasonic welding machines and the com-pany consumables have now been put into operation too

Complete welding of dumper trucksNow that Joskin has acquired a taste for ro-bot welding it has moved on to the welding of larger work pieces Joskin will be welding complete tipping units for its dumper trucks using the next welding cell which has now

been put together at Valk Welding in Alblas-serdam Didier Joskin ldquoThe technology is al-ready there as are the internal logistics The problem is building the right jigs With this new welding robot cell we plan to welding 6 dumper trucks a day in 15 shiftsrdquo

Credit crisis presents new opportunitiesBy using the new welding robot cells Joskin has succeeded in substantially increasing productivity without employing extra people Didier Joskin ldquoWhich is just as well as those extra people are difficult to find in our re-gion The high production rates have made it possible for us to reduce delivery times The reduced number of orders caused by the cre-dit crisis is creating more gaps in production and in the organisation At last we now have time to turn our attention to new markets We currently have a presence with our products in more than 30 countries and we are extending our network to Eastern Europe We are also increasing our marketing efforts to strengthen our position in the countries in which we already operaterdquo

Continued investment in welding robot technologyDidier Joskin ldquoOur outlook is good despite the somewhat weaker economic conditions We plan to continue to invest in welding robots in order to keep pace with the anti-cipated growth in turnover We will soon be delivering our 24000th tank and the 7000th dumper truckwwwjoskincom

Robot programmer Dominique Talmasse working on the welding program for welding complete dumper trucks in DTPS G2

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The huge welding robot system that Valk Welding has built for Bollegraaf Recycling Machinery in Appingedam forms part of a sizeable investment programme intended to double the production of bale presses within 2 years Bollegraaf is thus anticipating strong growth in the market for envi-ronmental and recycling technology As well as the welding robot system the DTPS G2 offline programme sy-stem and Valk Weldingrsquos Wire Wizard wire feed system the investment programme also covers a cutting line and a heavy-duty bending robot That will make it possible for the company to sharply reduce its lead times and to flexibly produce single articles

The welding robot system has a longitudinal movement of 33 metres with three trans-verse movements of 3 metres combined with a height movement of 19 metres The three Panasonic TA1900-WG welding robots are suspended on the height movement The work pieces are positioned by 2 manipulators with bearing capacities of 6 and 25 tonsOn the heaviest manipulator complete bale press frames are simultaneously welded by 2 robots The stamps and large valves for the compression section of the Bollegraaf bale presses are made at the second clamping area All three robots can work at the same time and the manipulators can even be stee-red individually That means that a total of 27 shafts can be steered separately

MasterpieceWith the 27 individually steered shafts this project makes full use of the functionalities of the offline programme system DTPS G2 The safety zones are of great importance because the three welding robots must not get in each otherrsquos way For the head of production Bram Bos offline programming was one of the most important preconditi-ons ldquoWe wanted to weld complete frames and also to be able to programme them entirely offline With that aim in mind our preparations included taking a close look at

various shipbuilding and trailer construction projects throughout Europe Valk Welding was the only robot integrator that had previously delivered such a heavy system including one to the Polish trailer building Wielton The decisive factor was the fact that Valk Welding is an organisation with high level technical knowledge of both robotics and weldingrdquo

Action planldquoGetting a project such as this off the ground is by no means an everyday event either for the supplier or for us Implementing a system like this involves a completely different working method which has to be supported by all departments Also it was necessary to create the right mindset for programming for single article production For that reason we created a large project team comprising 6 people from Bollegraaf and 5 from Valk Welding That means that RampD engineering and production people were closely involved in the completion of this project At the same time a number of employees were trained in programmingrdquo explains Bram Bos

Sharp reduction in lead timesAs well as the benefits of a high repetition precision business-economic considerations were of great importance to Bollegraafrsquos decision to give this automation operation

the green light Bollegraafrsquos welders needed a total of 2 weeks (including finishing) to manually weld frames for the bale presses with 3 layer angle welds The deployment of 2 welding robots reduced the cycle time for a complete frame to 21 hours Not only has that given Bollegraaf a substantial saving on wage costs the shorter lead times mean that it is no longer necessary to produce stock parts That fully meets the objective of raising flexibility and reducing stocks to zero

Thick plate softwareThe frames for Bollegraafrsquos bale presses are built up with 30mm steel plate Most of the welding is carried out with angle welds in three layers with 12 mm solid SG2 wire in A15 welding height The use of Thick Plate software makes it possible to automatically build up all layers with a robot program that only traces the first layer and fast access ma-cros are used to quickly and easily ascertain the tolerance in the product

Bollegraaf Recycling Machinery manufactures products including bale presses for waste paper and systems for processing industrial and domestic wastewwwbollegraafcom

Bollegraaf switches with welding robot cell to single-article production

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The company Faymonville the Bene-lux regionrsquos biggest manufacturer of semi-trailers for special transport has equipped all of its production units with Panasonic manual welding power sources Valk Welding has supplied the company with 250 manual welding machines over the past two years Faymonville uses these manual wel-ding power sources to completely weld heavy structural sections with lengths up to 18 metres The manual welding stations at Faymonville are also equip-ped with Wire Wizard welding wire feed systems in order to smoothly bridge the distance between the wel-

ding power source and the wire drive unit which in some cases exceeds a length of 12 metres

Faymonville has entered into a service contract with Valk Welding under which a unit price per year is paid for service and maintenance and the replacement of com-ponents This service contract has been taken out for a 10-year period after which it can be renewed for 2-year periods for each welding power source This service contract makes it possible for Faymonville to schedule the maintenance and overhaul costs for all of the organisationrsquos welding equipment Faymon-ville employs some 640 people Faymonville is now also using 4 welding robot systems wwwfaymonvillecom

Faymonville installs Panasonic manual welding machines throughout organisation

Valk Welding has recently supplied a combined arcstud welding system to the VDL Group The system is used to weld products for the car indus-try Products for this sector must be delivered absolutely free of defects The attachment of components using the stud welding method therefore has to be carried out fully automatically at all times To be completely certain that these studs have actually been attached the studs are welded onto the product by the robot

To have the arc welding and the stud welding carried out fully automatically with a single

robot the Panasonic arc welding robot is equipped with a Schunk tool changer That makes it possible for the robot to alternative fully automatically between the standard arc welding torch and the stud welding torch of Thomas Welding The stud welding head is equipped with a fully automatic feed that po-sitions the studs in the head The application of this special combination is the result of years of successful partnership between the VDL Group and Valk Welding and has led to a high degree of automation in several welding processes This system is the seventh arc welding robot that Valk Welding has installed within the VDL Group

See the video at wwwvalkweldingczvideosvideo_en_6html

Combined arcstud welding robot for VDL

Bollegraaf Recycling Machinery manufactu-res products including bale presses for waste paper and systems for processing industrial and domestic waste

Colophon

lsquoValk Mailingrsquo is a twice-yearly publication of Valk Welding BV and is sent free to all business relations If you want to receive this publication

in the future please send an email to infovalkweldingcom

The NetherlandsValk Welding BV

Staalindustrieweg 15PO Box 60

2950 AB AlblasserdamTel +31 78 69 170 11Fax +31 78 69 195 15

infovalkweldingcomwwwvalkweldingcom

BelgiumTel +32 (0)3 685 14 77Fax +32 (0)3 685 12 33

France Valk Welding France

Tel +33 (0)3 20 10 00 39Fax +33 (0)3 20 10 01 12

DenmarkValk Welding DK AS Tel +45 64421201Fax +45 64421202

Czech RepublicValk Welding CZ sro

Tel +420 556 73 0954Fax +420 556 73 1680

ProductionSteenkist Communicatie NL-Haarlem

steencomtiscalinl

PhotographyValk Welding BV

Erik Steenkist Marko bv Bollegraaf

Trade Fairs and Events

Vision amp Robotics Nieuwegein The Netherlands

16-17 June 2009

Schweissen und Schneiden Essen Germany

14-19 September 2009

Eurowelding ndash MSV 2009 Brno Czech Republic

14-18 September 2009

Metavak Gorinchem The Netherlands

10-12 November 2009

-

Marko installs fourth genera-tion welding robot system In spring of this year furniture produ-cer Marko BV put a new advanced welding robot system into operation at its production facility in Veendam The welding robot system represents the companyrsquos fourth generation of welding robots Marko was leading the way in the robotised welding of steel office and school furniture as far back as in the nineteen-eighties The investment in a Panasonic Tawers welding robot on a longitudinal movement and with 8 work stations has provided Marko with the last word in welding robot technology Marko is thus setting out to guaran-tee its product quality and production efficiency in the years to come

Higher capacity utilisation levelThe ample number of work stations makes it possible to limit the number of tool changes which leads to increased in productivity and flexibility That has increased the capacity utilisation level compared to the previous system The DTPS G2 offline programming system makes it possible to convert the programs of the older robots for the new robot system Also new products can be programmed offline and are easy to transfer or copy to other work stationsMarko achieves 80 of its turnover with school furniture and sets out to compete with its products mainly on quality With this strategy the company has succeeded in gaining a leading market position in the Benelux region wwwmarkoinfo

To overcome language barriers between French-speaking clients and the Dutch Valk Welding organi-sation telephone calls from France are first put directly through to our French-speaking office worker Fabrice Lefegravevre The need to communicate in French with the Dutch head office of Valk Welding had come about owing to the growth in the number of Fre-nch-speaking clients and the exten-sion of the sales activities caused by the incorporation of Valk Welding France Atlantique

Fabrice Lefegravevre is a Frenchman who has lived for more than 25 years in the Netherlands and has worked at Valk Welding in Alblasserdam since February of this

year Fabrice has a technical background in the bodywork sector and has broad know-ledge of welding technology which ideally places him to give clients an optimum service for both technical and administra-tive issues He thus forms the pivot between French-speaking clients and the Dutch Valk Welding organisation and supports the field service staff of Valk Welding France and Valk Welding France Atlantique

Fabrice Lefegravevre pivot between French clients and the Valk Welding organisation

Video ArchiveWant to see how it works Watch the videos of current robot projects atwwwvalkweldingczvideos

Page 4: 2009-01-Valk Mailing-EN

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Employing more than 650 people and with locations in Belgium France and Poland Joskin is currently one of Europersquos biggest agricultural vehicle producers The companyrsquos growth gained momentum as a result of a number of successful products for which Joskin produces all of the parts under its own management The company has trebled its turnover since opening production facilities in France and Poland

Initially tired of robotsIt will go without saying that a company of this size started using welding robots at an early stage But Joskin had never succeeded in achieving the desired result with them Pro-duction manager Didier Joskin explains the reasons for that ldquoThe operator was spending more time on programming and optimising the robots than on production We also had a lot of calibration problems and were unable to weld a number of products That led to serious delays in the cycle times and ultima-tely resulted in poor productivity levels Until recently we were pretty tired of robots We even considered switching to manual welding at our locations in Belgium and Polandrdquo

Valk Welding convincedWithout much hope in the summer of 2006 Joskin asked a number of suppliers to make

a proposal mainly aimed at achieving a rise in productivity and flexibility and improving the quality of the products for which welding robots were used Didier Joskin As a test object we gave them a hydraulic cylinder the product we have had the most trouble with Based on sound preparations Valk Welding delivered a perfect product and managed to put forward convincing arguments both on the technical front and at company level with its facilities in Alblasserdam It also became clear that the two companies had more in common than apparent at first glance a strong family firm character with enthusias-tic personnel a leading market position with a technically cutting edge product and strong growth combined with a healthy outlook

We decided to put the new Valk Welding system into operation as a pilot After that everything moved very quickly The quality was perfect the productivity rate was 25 to 50 higher we had no malfunctions and the setup time turned out to be many times shorter than what we were accustomed to That prompted our decision to replace all six existing welding robots with Panasonic TAWERS welding robotsrdquo

Hydraulic cylinders Joskin was experiencing the most problems

with the robotised welding of its hydraulic cylinders The success of this product was therefore an important factor in Joskinrsquos decision on whether to continue with robot welding Peter Pittomvils Valk Weldingrsquos technical consultant ldquoJoskin makes all of the hydraulic cylinders for its vehicles under its own management If you look at Joskinrsquos wide range of products that will give you an impression of the numbers That meant that robot welding would have benefits The main problem was found in welding the nipple on the cylinder The strong concentration of heat on a small area made it impossible to make the cylinder optimally round We managed to achieve that on the basis of our expertise and by using the new SP-MAG welding processrdquo

Standard systems for sub-assemblies Of the seven welding robots that Valk Welding has supplied to Joskin the first four are based on an H-frame concept with two clamping tables a manipulator and high speed doors Joskin used this relatively simple setup for welding small parts and sub-assem-blies To have a welding robot operate several clamping tables a fifth cell was fitted with a robot on a longitudinal travel This setup made it possible to achieve a long activation period for the welding robot The work pieces were clamped and taken out while the robot

Joskin which manufactures vehicles for manure spreading and agricultural transport systems has in recent years invested substantially in increasing its capacity and moder-nising its welding department Seven welding robot systems have now been put into operation at the production facility in Soumagne close to Luik and there are more to come Joskin has thus succeeded not only in sharply raising produc-tivity but also in achieving a higher and more consistent level of quality Joskin has opted for the latest welding robot technology of the Panasonic TAWERS welding robots and the DTPS G2 offline program-ming system

Detail of special jigs for welding hydraulic cylinders Didier Joskin

Joskin raises productivity with latest welding robot technology

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Dominique Talmasse (r) robot programmer at Joskin and Peter Pittomvils sales manager Belgium of Valk Welding

Standard welding robot cell with two clamping tables and high speed door

3D simulation in DTPS G2 of the welding robot cell under construction that Joskin plans to use to weld complete dumper trucks

Joskin raises productivity with latest welding robot technology

was welding at another station A further two standard cells have recently been added Didier Joskin ldquoBy using seven cells wersquove succeeded in making more products with one less shift and have fully integrated all of the welding work This has also given us a guarantee of extra capacity in the futurerdquo

Latest generation of welding robotsFor the new welding robot cells Valk Welding has deployed the latest generation of Panasonicrsquos TAWERS welding robots With this robot which has been purpose built for arc welding the welding machine and the robot are integrated in a single control system The extremely high communication speeds that this achieves make the TAWERS the most advanced and fast welding robot on the market Didier Joskin ldquoThe TAWERS welding robot is a typically advanced top quality Japanese product with a high level of reliability and which is easy to programme The welding current source is unique and facilitates many software functionalities including a spat-free welding process and integrated welding data registration The col-lision detector is especially important to us In the event of a collision the welding robot switches to softndashservo which makes the robot arm lsquopliantrsquo so that no damage can be caused to the torch or robot arm and does away with the need to recalibraterdquo

Offline programmingOffline programming contributes signi-ficantly to the productivity gains of the TAWERS welding robots Valk Welding has been successfully using the programming

and simulation system DTPS G2 which it had a hand in developing for more than ten years That gives the robot operator control over the entire welding production process and also makes it possible for him to prepare welding programmes outside of production That not only yields a higher welding robot activation level but also facilitates a high level of flexibility For that reason it is no longer the size of the series that determi-nes whether profitable use can be made of welding robots

Total solution partnerJoskin was aware that outstanding quality and a fault-free supply of welding wire were vital to achieving maximum output That is why Joskin performed tests - free of obligation - with Valk Weldingrsquos solid welding wire in Ecodrums Much to Joskinrsquos surprise as well as the spat-free end result the wire feed with this welding wire was entirely faultless The price and production benefits were reason enough for Joskin to switch all of its robots to Valk Weldingrsquos welding wire Also with Valk Welding as a ldquoTotal Solution Partnerrdquo Joskin only has to deal with a single point of contact As well as the welding wire Panasonic welding machines and the com-pany consumables have now been put into operation too

Complete welding of dumper trucksNow that Joskin has acquired a taste for ro-bot welding it has moved on to the welding of larger work pieces Joskin will be welding complete tipping units for its dumper trucks using the next welding cell which has now

been put together at Valk Welding in Alblas-serdam Didier Joskin ldquoThe technology is al-ready there as are the internal logistics The problem is building the right jigs With this new welding robot cell we plan to welding 6 dumper trucks a day in 15 shiftsrdquo

Credit crisis presents new opportunitiesBy using the new welding robot cells Joskin has succeeded in substantially increasing productivity without employing extra people Didier Joskin ldquoWhich is just as well as those extra people are difficult to find in our re-gion The high production rates have made it possible for us to reduce delivery times The reduced number of orders caused by the cre-dit crisis is creating more gaps in production and in the organisation At last we now have time to turn our attention to new markets We currently have a presence with our products in more than 30 countries and we are extending our network to Eastern Europe We are also increasing our marketing efforts to strengthen our position in the countries in which we already operaterdquo

Continued investment in welding robot technologyDidier Joskin ldquoOur outlook is good despite the somewhat weaker economic conditions We plan to continue to invest in welding robots in order to keep pace with the anti-cipated growth in turnover We will soon be delivering our 24000th tank and the 7000th dumper truckwwwjoskincom

Robot programmer Dominique Talmasse working on the welding program for welding complete dumper trucks in DTPS G2

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The huge welding robot system that Valk Welding has built for Bollegraaf Recycling Machinery in Appingedam forms part of a sizeable investment programme intended to double the production of bale presses within 2 years Bollegraaf is thus anticipating strong growth in the market for envi-ronmental and recycling technology As well as the welding robot system the DTPS G2 offline programme sy-stem and Valk Weldingrsquos Wire Wizard wire feed system the investment programme also covers a cutting line and a heavy-duty bending robot That will make it possible for the company to sharply reduce its lead times and to flexibly produce single articles

The welding robot system has a longitudinal movement of 33 metres with three trans-verse movements of 3 metres combined with a height movement of 19 metres The three Panasonic TA1900-WG welding robots are suspended on the height movement The work pieces are positioned by 2 manipulators with bearing capacities of 6 and 25 tonsOn the heaviest manipulator complete bale press frames are simultaneously welded by 2 robots The stamps and large valves for the compression section of the Bollegraaf bale presses are made at the second clamping area All three robots can work at the same time and the manipulators can even be stee-red individually That means that a total of 27 shafts can be steered separately

MasterpieceWith the 27 individually steered shafts this project makes full use of the functionalities of the offline programme system DTPS G2 The safety zones are of great importance because the three welding robots must not get in each otherrsquos way For the head of production Bram Bos offline programming was one of the most important preconditi-ons ldquoWe wanted to weld complete frames and also to be able to programme them entirely offline With that aim in mind our preparations included taking a close look at

various shipbuilding and trailer construction projects throughout Europe Valk Welding was the only robot integrator that had previously delivered such a heavy system including one to the Polish trailer building Wielton The decisive factor was the fact that Valk Welding is an organisation with high level technical knowledge of both robotics and weldingrdquo

Action planldquoGetting a project such as this off the ground is by no means an everyday event either for the supplier or for us Implementing a system like this involves a completely different working method which has to be supported by all departments Also it was necessary to create the right mindset for programming for single article production For that reason we created a large project team comprising 6 people from Bollegraaf and 5 from Valk Welding That means that RampD engineering and production people were closely involved in the completion of this project At the same time a number of employees were trained in programmingrdquo explains Bram Bos

Sharp reduction in lead timesAs well as the benefits of a high repetition precision business-economic considerations were of great importance to Bollegraafrsquos decision to give this automation operation

the green light Bollegraafrsquos welders needed a total of 2 weeks (including finishing) to manually weld frames for the bale presses with 3 layer angle welds The deployment of 2 welding robots reduced the cycle time for a complete frame to 21 hours Not only has that given Bollegraaf a substantial saving on wage costs the shorter lead times mean that it is no longer necessary to produce stock parts That fully meets the objective of raising flexibility and reducing stocks to zero

Thick plate softwareThe frames for Bollegraafrsquos bale presses are built up with 30mm steel plate Most of the welding is carried out with angle welds in three layers with 12 mm solid SG2 wire in A15 welding height The use of Thick Plate software makes it possible to automatically build up all layers with a robot program that only traces the first layer and fast access ma-cros are used to quickly and easily ascertain the tolerance in the product

Bollegraaf Recycling Machinery manufactures products including bale presses for waste paper and systems for processing industrial and domestic wastewwwbollegraafcom

Bollegraaf switches with welding robot cell to single-article production

VA

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97

The company Faymonville the Bene-lux regionrsquos biggest manufacturer of semi-trailers for special transport has equipped all of its production units with Panasonic manual welding power sources Valk Welding has supplied the company with 250 manual welding machines over the past two years Faymonville uses these manual wel-ding power sources to completely weld heavy structural sections with lengths up to 18 metres The manual welding stations at Faymonville are also equip-ped with Wire Wizard welding wire feed systems in order to smoothly bridge the distance between the wel-

ding power source and the wire drive unit which in some cases exceeds a length of 12 metres

Faymonville has entered into a service contract with Valk Welding under which a unit price per year is paid for service and maintenance and the replacement of com-ponents This service contract has been taken out for a 10-year period after which it can be renewed for 2-year periods for each welding power source This service contract makes it possible for Faymonville to schedule the maintenance and overhaul costs for all of the organisationrsquos welding equipment Faymon-ville employs some 640 people Faymonville is now also using 4 welding robot systems wwwfaymonvillecom

Faymonville installs Panasonic manual welding machines throughout organisation

Valk Welding has recently supplied a combined arcstud welding system to the VDL Group The system is used to weld products for the car indus-try Products for this sector must be delivered absolutely free of defects The attachment of components using the stud welding method therefore has to be carried out fully automatically at all times To be completely certain that these studs have actually been attached the studs are welded onto the product by the robot

To have the arc welding and the stud welding carried out fully automatically with a single

robot the Panasonic arc welding robot is equipped with a Schunk tool changer That makes it possible for the robot to alternative fully automatically between the standard arc welding torch and the stud welding torch of Thomas Welding The stud welding head is equipped with a fully automatic feed that po-sitions the studs in the head The application of this special combination is the result of years of successful partnership between the VDL Group and Valk Welding and has led to a high degree of automation in several welding processes This system is the seventh arc welding robot that Valk Welding has installed within the VDL Group

See the video at wwwvalkweldingczvideosvideo_en_6html

Combined arcstud welding robot for VDL

Bollegraaf Recycling Machinery manufactu-res products including bale presses for waste paper and systems for processing industrial and domestic waste

Colophon

lsquoValk Mailingrsquo is a twice-yearly publication of Valk Welding BV and is sent free to all business relations If you want to receive this publication

in the future please send an email to infovalkweldingcom

The NetherlandsValk Welding BV

Staalindustrieweg 15PO Box 60

2950 AB AlblasserdamTel +31 78 69 170 11Fax +31 78 69 195 15

infovalkweldingcomwwwvalkweldingcom

BelgiumTel +32 (0)3 685 14 77Fax +32 (0)3 685 12 33

France Valk Welding France

Tel +33 (0)3 20 10 00 39Fax +33 (0)3 20 10 01 12

DenmarkValk Welding DK AS Tel +45 64421201Fax +45 64421202

Czech RepublicValk Welding CZ sro

Tel +420 556 73 0954Fax +420 556 73 1680

ProductionSteenkist Communicatie NL-Haarlem

steencomtiscalinl

PhotographyValk Welding BV

Erik Steenkist Marko bv Bollegraaf

Trade Fairs and Events

Vision amp Robotics Nieuwegein The Netherlands

16-17 June 2009

Schweissen und Schneiden Essen Germany

14-19 September 2009

Eurowelding ndash MSV 2009 Brno Czech Republic

14-18 September 2009

Metavak Gorinchem The Netherlands

10-12 November 2009

-

Marko installs fourth genera-tion welding robot system In spring of this year furniture produ-cer Marko BV put a new advanced welding robot system into operation at its production facility in Veendam The welding robot system represents the companyrsquos fourth generation of welding robots Marko was leading the way in the robotised welding of steel office and school furniture as far back as in the nineteen-eighties The investment in a Panasonic Tawers welding robot on a longitudinal movement and with 8 work stations has provided Marko with the last word in welding robot technology Marko is thus setting out to guaran-tee its product quality and production efficiency in the years to come

Higher capacity utilisation levelThe ample number of work stations makes it possible to limit the number of tool changes which leads to increased in productivity and flexibility That has increased the capacity utilisation level compared to the previous system The DTPS G2 offline programming system makes it possible to convert the programs of the older robots for the new robot system Also new products can be programmed offline and are easy to transfer or copy to other work stationsMarko achieves 80 of its turnover with school furniture and sets out to compete with its products mainly on quality With this strategy the company has succeeded in gaining a leading market position in the Benelux region wwwmarkoinfo

To overcome language barriers between French-speaking clients and the Dutch Valk Welding organi-sation telephone calls from France are first put directly through to our French-speaking office worker Fabrice Lefegravevre The need to communicate in French with the Dutch head office of Valk Welding had come about owing to the growth in the number of Fre-nch-speaking clients and the exten-sion of the sales activities caused by the incorporation of Valk Welding France Atlantique

Fabrice Lefegravevre is a Frenchman who has lived for more than 25 years in the Netherlands and has worked at Valk Welding in Alblasserdam since February of this

year Fabrice has a technical background in the bodywork sector and has broad know-ledge of welding technology which ideally places him to give clients an optimum service for both technical and administra-tive issues He thus forms the pivot between French-speaking clients and the Dutch Valk Welding organisation and supports the field service staff of Valk Welding France and Valk Welding France Atlantique

Fabrice Lefegravevre pivot between French clients and the Valk Welding organisation

Video ArchiveWant to see how it works Watch the videos of current robot projects atwwwvalkweldingczvideos

Page 5: 2009-01-Valk Mailing-EN

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Dominique Talmasse (r) robot programmer at Joskin and Peter Pittomvils sales manager Belgium of Valk Welding

Standard welding robot cell with two clamping tables and high speed door

3D simulation in DTPS G2 of the welding robot cell under construction that Joskin plans to use to weld complete dumper trucks

Joskin raises productivity with latest welding robot technology

was welding at another station A further two standard cells have recently been added Didier Joskin ldquoBy using seven cells wersquove succeeded in making more products with one less shift and have fully integrated all of the welding work This has also given us a guarantee of extra capacity in the futurerdquo

Latest generation of welding robotsFor the new welding robot cells Valk Welding has deployed the latest generation of Panasonicrsquos TAWERS welding robots With this robot which has been purpose built for arc welding the welding machine and the robot are integrated in a single control system The extremely high communication speeds that this achieves make the TAWERS the most advanced and fast welding robot on the market Didier Joskin ldquoThe TAWERS welding robot is a typically advanced top quality Japanese product with a high level of reliability and which is easy to programme The welding current source is unique and facilitates many software functionalities including a spat-free welding process and integrated welding data registration The col-lision detector is especially important to us In the event of a collision the welding robot switches to softndashservo which makes the robot arm lsquopliantrsquo so that no damage can be caused to the torch or robot arm and does away with the need to recalibraterdquo

Offline programmingOffline programming contributes signi-ficantly to the productivity gains of the TAWERS welding robots Valk Welding has been successfully using the programming

and simulation system DTPS G2 which it had a hand in developing for more than ten years That gives the robot operator control over the entire welding production process and also makes it possible for him to prepare welding programmes outside of production That not only yields a higher welding robot activation level but also facilitates a high level of flexibility For that reason it is no longer the size of the series that determi-nes whether profitable use can be made of welding robots

Total solution partnerJoskin was aware that outstanding quality and a fault-free supply of welding wire were vital to achieving maximum output That is why Joskin performed tests - free of obligation - with Valk Weldingrsquos solid welding wire in Ecodrums Much to Joskinrsquos surprise as well as the spat-free end result the wire feed with this welding wire was entirely faultless The price and production benefits were reason enough for Joskin to switch all of its robots to Valk Weldingrsquos welding wire Also with Valk Welding as a ldquoTotal Solution Partnerrdquo Joskin only has to deal with a single point of contact As well as the welding wire Panasonic welding machines and the com-pany consumables have now been put into operation too

Complete welding of dumper trucksNow that Joskin has acquired a taste for ro-bot welding it has moved on to the welding of larger work pieces Joskin will be welding complete tipping units for its dumper trucks using the next welding cell which has now

been put together at Valk Welding in Alblas-serdam Didier Joskin ldquoThe technology is al-ready there as are the internal logistics The problem is building the right jigs With this new welding robot cell we plan to welding 6 dumper trucks a day in 15 shiftsrdquo

Credit crisis presents new opportunitiesBy using the new welding robot cells Joskin has succeeded in substantially increasing productivity without employing extra people Didier Joskin ldquoWhich is just as well as those extra people are difficult to find in our re-gion The high production rates have made it possible for us to reduce delivery times The reduced number of orders caused by the cre-dit crisis is creating more gaps in production and in the organisation At last we now have time to turn our attention to new markets We currently have a presence with our products in more than 30 countries and we are extending our network to Eastern Europe We are also increasing our marketing efforts to strengthen our position in the countries in which we already operaterdquo

Continued investment in welding robot technologyDidier Joskin ldquoOur outlook is good despite the somewhat weaker economic conditions We plan to continue to invest in welding robots in order to keep pace with the anti-cipated growth in turnover We will soon be delivering our 24000th tank and the 7000th dumper truckwwwjoskincom

Robot programmer Dominique Talmasse working on the welding program for welding complete dumper trucks in DTPS G2

VA

LK

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96

The huge welding robot system that Valk Welding has built for Bollegraaf Recycling Machinery in Appingedam forms part of a sizeable investment programme intended to double the production of bale presses within 2 years Bollegraaf is thus anticipating strong growth in the market for envi-ronmental and recycling technology As well as the welding robot system the DTPS G2 offline programme sy-stem and Valk Weldingrsquos Wire Wizard wire feed system the investment programme also covers a cutting line and a heavy-duty bending robot That will make it possible for the company to sharply reduce its lead times and to flexibly produce single articles

The welding robot system has a longitudinal movement of 33 metres with three trans-verse movements of 3 metres combined with a height movement of 19 metres The three Panasonic TA1900-WG welding robots are suspended on the height movement The work pieces are positioned by 2 manipulators with bearing capacities of 6 and 25 tonsOn the heaviest manipulator complete bale press frames are simultaneously welded by 2 robots The stamps and large valves for the compression section of the Bollegraaf bale presses are made at the second clamping area All three robots can work at the same time and the manipulators can even be stee-red individually That means that a total of 27 shafts can be steered separately

MasterpieceWith the 27 individually steered shafts this project makes full use of the functionalities of the offline programme system DTPS G2 The safety zones are of great importance because the three welding robots must not get in each otherrsquos way For the head of production Bram Bos offline programming was one of the most important preconditi-ons ldquoWe wanted to weld complete frames and also to be able to programme them entirely offline With that aim in mind our preparations included taking a close look at

various shipbuilding and trailer construction projects throughout Europe Valk Welding was the only robot integrator that had previously delivered such a heavy system including one to the Polish trailer building Wielton The decisive factor was the fact that Valk Welding is an organisation with high level technical knowledge of both robotics and weldingrdquo

Action planldquoGetting a project such as this off the ground is by no means an everyday event either for the supplier or for us Implementing a system like this involves a completely different working method which has to be supported by all departments Also it was necessary to create the right mindset for programming for single article production For that reason we created a large project team comprising 6 people from Bollegraaf and 5 from Valk Welding That means that RampD engineering and production people were closely involved in the completion of this project At the same time a number of employees were trained in programmingrdquo explains Bram Bos

Sharp reduction in lead timesAs well as the benefits of a high repetition precision business-economic considerations were of great importance to Bollegraafrsquos decision to give this automation operation

the green light Bollegraafrsquos welders needed a total of 2 weeks (including finishing) to manually weld frames for the bale presses with 3 layer angle welds The deployment of 2 welding robots reduced the cycle time for a complete frame to 21 hours Not only has that given Bollegraaf a substantial saving on wage costs the shorter lead times mean that it is no longer necessary to produce stock parts That fully meets the objective of raising flexibility and reducing stocks to zero

Thick plate softwareThe frames for Bollegraafrsquos bale presses are built up with 30mm steel plate Most of the welding is carried out with angle welds in three layers with 12 mm solid SG2 wire in A15 welding height The use of Thick Plate software makes it possible to automatically build up all layers with a robot program that only traces the first layer and fast access ma-cros are used to quickly and easily ascertain the tolerance in the product

Bollegraaf Recycling Machinery manufactures products including bale presses for waste paper and systems for processing industrial and domestic wastewwwbollegraafcom

Bollegraaf switches with welding robot cell to single-article production

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The company Faymonville the Bene-lux regionrsquos biggest manufacturer of semi-trailers for special transport has equipped all of its production units with Panasonic manual welding power sources Valk Welding has supplied the company with 250 manual welding machines over the past two years Faymonville uses these manual wel-ding power sources to completely weld heavy structural sections with lengths up to 18 metres The manual welding stations at Faymonville are also equip-ped with Wire Wizard welding wire feed systems in order to smoothly bridge the distance between the wel-

ding power source and the wire drive unit which in some cases exceeds a length of 12 metres

Faymonville has entered into a service contract with Valk Welding under which a unit price per year is paid for service and maintenance and the replacement of com-ponents This service contract has been taken out for a 10-year period after which it can be renewed for 2-year periods for each welding power source This service contract makes it possible for Faymonville to schedule the maintenance and overhaul costs for all of the organisationrsquos welding equipment Faymon-ville employs some 640 people Faymonville is now also using 4 welding robot systems wwwfaymonvillecom

Faymonville installs Panasonic manual welding machines throughout organisation

Valk Welding has recently supplied a combined arcstud welding system to the VDL Group The system is used to weld products for the car indus-try Products for this sector must be delivered absolutely free of defects The attachment of components using the stud welding method therefore has to be carried out fully automatically at all times To be completely certain that these studs have actually been attached the studs are welded onto the product by the robot

To have the arc welding and the stud welding carried out fully automatically with a single

robot the Panasonic arc welding robot is equipped with a Schunk tool changer That makes it possible for the robot to alternative fully automatically between the standard arc welding torch and the stud welding torch of Thomas Welding The stud welding head is equipped with a fully automatic feed that po-sitions the studs in the head The application of this special combination is the result of years of successful partnership between the VDL Group and Valk Welding and has led to a high degree of automation in several welding processes This system is the seventh arc welding robot that Valk Welding has installed within the VDL Group

See the video at wwwvalkweldingczvideosvideo_en_6html

Combined arcstud welding robot for VDL

Bollegraaf Recycling Machinery manufactu-res products including bale presses for waste paper and systems for processing industrial and domestic waste

Colophon

lsquoValk Mailingrsquo is a twice-yearly publication of Valk Welding BV and is sent free to all business relations If you want to receive this publication

in the future please send an email to infovalkweldingcom

The NetherlandsValk Welding BV

Staalindustrieweg 15PO Box 60

2950 AB AlblasserdamTel +31 78 69 170 11Fax +31 78 69 195 15

infovalkweldingcomwwwvalkweldingcom

BelgiumTel +32 (0)3 685 14 77Fax +32 (0)3 685 12 33

France Valk Welding France

Tel +33 (0)3 20 10 00 39Fax +33 (0)3 20 10 01 12

DenmarkValk Welding DK AS Tel +45 64421201Fax +45 64421202

Czech RepublicValk Welding CZ sro

Tel +420 556 73 0954Fax +420 556 73 1680

ProductionSteenkist Communicatie NL-Haarlem

steencomtiscalinl

PhotographyValk Welding BV

Erik Steenkist Marko bv Bollegraaf

Trade Fairs and Events

Vision amp Robotics Nieuwegein The Netherlands

16-17 June 2009

Schweissen und Schneiden Essen Germany

14-19 September 2009

Eurowelding ndash MSV 2009 Brno Czech Republic

14-18 September 2009

Metavak Gorinchem The Netherlands

10-12 November 2009

-

Marko installs fourth genera-tion welding robot system In spring of this year furniture produ-cer Marko BV put a new advanced welding robot system into operation at its production facility in Veendam The welding robot system represents the companyrsquos fourth generation of welding robots Marko was leading the way in the robotised welding of steel office and school furniture as far back as in the nineteen-eighties The investment in a Panasonic Tawers welding robot on a longitudinal movement and with 8 work stations has provided Marko with the last word in welding robot technology Marko is thus setting out to guaran-tee its product quality and production efficiency in the years to come

Higher capacity utilisation levelThe ample number of work stations makes it possible to limit the number of tool changes which leads to increased in productivity and flexibility That has increased the capacity utilisation level compared to the previous system The DTPS G2 offline programming system makes it possible to convert the programs of the older robots for the new robot system Also new products can be programmed offline and are easy to transfer or copy to other work stationsMarko achieves 80 of its turnover with school furniture and sets out to compete with its products mainly on quality With this strategy the company has succeeded in gaining a leading market position in the Benelux region wwwmarkoinfo

To overcome language barriers between French-speaking clients and the Dutch Valk Welding organi-sation telephone calls from France are first put directly through to our French-speaking office worker Fabrice Lefegravevre The need to communicate in French with the Dutch head office of Valk Welding had come about owing to the growth in the number of Fre-nch-speaking clients and the exten-sion of the sales activities caused by the incorporation of Valk Welding France Atlantique

Fabrice Lefegravevre is a Frenchman who has lived for more than 25 years in the Netherlands and has worked at Valk Welding in Alblasserdam since February of this

year Fabrice has a technical background in the bodywork sector and has broad know-ledge of welding technology which ideally places him to give clients an optimum service for both technical and administra-tive issues He thus forms the pivot between French-speaking clients and the Dutch Valk Welding organisation and supports the field service staff of Valk Welding France and Valk Welding France Atlantique

Fabrice Lefegravevre pivot between French clients and the Valk Welding organisation

Video ArchiveWant to see how it works Watch the videos of current robot projects atwwwvalkweldingczvideos

Page 6: 2009-01-Valk Mailing-EN

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The huge welding robot system that Valk Welding has built for Bollegraaf Recycling Machinery in Appingedam forms part of a sizeable investment programme intended to double the production of bale presses within 2 years Bollegraaf is thus anticipating strong growth in the market for envi-ronmental and recycling technology As well as the welding robot system the DTPS G2 offline programme sy-stem and Valk Weldingrsquos Wire Wizard wire feed system the investment programme also covers a cutting line and a heavy-duty bending robot That will make it possible for the company to sharply reduce its lead times and to flexibly produce single articles

The welding robot system has a longitudinal movement of 33 metres with three trans-verse movements of 3 metres combined with a height movement of 19 metres The three Panasonic TA1900-WG welding robots are suspended on the height movement The work pieces are positioned by 2 manipulators with bearing capacities of 6 and 25 tonsOn the heaviest manipulator complete bale press frames are simultaneously welded by 2 robots The stamps and large valves for the compression section of the Bollegraaf bale presses are made at the second clamping area All three robots can work at the same time and the manipulators can even be stee-red individually That means that a total of 27 shafts can be steered separately

MasterpieceWith the 27 individually steered shafts this project makes full use of the functionalities of the offline programme system DTPS G2 The safety zones are of great importance because the three welding robots must not get in each otherrsquos way For the head of production Bram Bos offline programming was one of the most important preconditi-ons ldquoWe wanted to weld complete frames and also to be able to programme them entirely offline With that aim in mind our preparations included taking a close look at

various shipbuilding and trailer construction projects throughout Europe Valk Welding was the only robot integrator that had previously delivered such a heavy system including one to the Polish trailer building Wielton The decisive factor was the fact that Valk Welding is an organisation with high level technical knowledge of both robotics and weldingrdquo

Action planldquoGetting a project such as this off the ground is by no means an everyday event either for the supplier or for us Implementing a system like this involves a completely different working method which has to be supported by all departments Also it was necessary to create the right mindset for programming for single article production For that reason we created a large project team comprising 6 people from Bollegraaf and 5 from Valk Welding That means that RampD engineering and production people were closely involved in the completion of this project At the same time a number of employees were trained in programmingrdquo explains Bram Bos

Sharp reduction in lead timesAs well as the benefits of a high repetition precision business-economic considerations were of great importance to Bollegraafrsquos decision to give this automation operation

the green light Bollegraafrsquos welders needed a total of 2 weeks (including finishing) to manually weld frames for the bale presses with 3 layer angle welds The deployment of 2 welding robots reduced the cycle time for a complete frame to 21 hours Not only has that given Bollegraaf a substantial saving on wage costs the shorter lead times mean that it is no longer necessary to produce stock parts That fully meets the objective of raising flexibility and reducing stocks to zero

Thick plate softwareThe frames for Bollegraafrsquos bale presses are built up with 30mm steel plate Most of the welding is carried out with angle welds in three layers with 12 mm solid SG2 wire in A15 welding height The use of Thick Plate software makes it possible to automatically build up all layers with a robot program that only traces the first layer and fast access ma-cros are used to quickly and easily ascertain the tolerance in the product

Bollegraaf Recycling Machinery manufactures products including bale presses for waste paper and systems for processing industrial and domestic wastewwwbollegraafcom

Bollegraaf switches with welding robot cell to single-article production

VA

LK

MA

ILIN

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00

97

The company Faymonville the Bene-lux regionrsquos biggest manufacturer of semi-trailers for special transport has equipped all of its production units with Panasonic manual welding power sources Valk Welding has supplied the company with 250 manual welding machines over the past two years Faymonville uses these manual wel-ding power sources to completely weld heavy structural sections with lengths up to 18 metres The manual welding stations at Faymonville are also equip-ped with Wire Wizard welding wire feed systems in order to smoothly bridge the distance between the wel-

ding power source and the wire drive unit which in some cases exceeds a length of 12 metres

Faymonville has entered into a service contract with Valk Welding under which a unit price per year is paid for service and maintenance and the replacement of com-ponents This service contract has been taken out for a 10-year period after which it can be renewed for 2-year periods for each welding power source This service contract makes it possible for Faymonville to schedule the maintenance and overhaul costs for all of the organisationrsquos welding equipment Faymon-ville employs some 640 people Faymonville is now also using 4 welding robot systems wwwfaymonvillecom

Faymonville installs Panasonic manual welding machines throughout organisation

Valk Welding has recently supplied a combined arcstud welding system to the VDL Group The system is used to weld products for the car indus-try Products for this sector must be delivered absolutely free of defects The attachment of components using the stud welding method therefore has to be carried out fully automatically at all times To be completely certain that these studs have actually been attached the studs are welded onto the product by the robot

To have the arc welding and the stud welding carried out fully automatically with a single

robot the Panasonic arc welding robot is equipped with a Schunk tool changer That makes it possible for the robot to alternative fully automatically between the standard arc welding torch and the stud welding torch of Thomas Welding The stud welding head is equipped with a fully automatic feed that po-sitions the studs in the head The application of this special combination is the result of years of successful partnership between the VDL Group and Valk Welding and has led to a high degree of automation in several welding processes This system is the seventh arc welding robot that Valk Welding has installed within the VDL Group

See the video at wwwvalkweldingczvideosvideo_en_6html

Combined arcstud welding robot for VDL

Bollegraaf Recycling Machinery manufactu-res products including bale presses for waste paper and systems for processing industrial and domestic waste

Colophon

lsquoValk Mailingrsquo is a twice-yearly publication of Valk Welding BV and is sent free to all business relations If you want to receive this publication

in the future please send an email to infovalkweldingcom

The NetherlandsValk Welding BV

Staalindustrieweg 15PO Box 60

2950 AB AlblasserdamTel +31 78 69 170 11Fax +31 78 69 195 15

infovalkweldingcomwwwvalkweldingcom

BelgiumTel +32 (0)3 685 14 77Fax +32 (0)3 685 12 33

France Valk Welding France

Tel +33 (0)3 20 10 00 39Fax +33 (0)3 20 10 01 12

DenmarkValk Welding DK AS Tel +45 64421201Fax +45 64421202

Czech RepublicValk Welding CZ sro

Tel +420 556 73 0954Fax +420 556 73 1680

ProductionSteenkist Communicatie NL-Haarlem

steencomtiscalinl

PhotographyValk Welding BV

Erik Steenkist Marko bv Bollegraaf

Trade Fairs and Events

Vision amp Robotics Nieuwegein The Netherlands

16-17 June 2009

Schweissen und Schneiden Essen Germany

14-19 September 2009

Eurowelding ndash MSV 2009 Brno Czech Republic

14-18 September 2009

Metavak Gorinchem The Netherlands

10-12 November 2009

-

Marko installs fourth genera-tion welding robot system In spring of this year furniture produ-cer Marko BV put a new advanced welding robot system into operation at its production facility in Veendam The welding robot system represents the companyrsquos fourth generation of welding robots Marko was leading the way in the robotised welding of steel office and school furniture as far back as in the nineteen-eighties The investment in a Panasonic Tawers welding robot on a longitudinal movement and with 8 work stations has provided Marko with the last word in welding robot technology Marko is thus setting out to guaran-tee its product quality and production efficiency in the years to come

Higher capacity utilisation levelThe ample number of work stations makes it possible to limit the number of tool changes which leads to increased in productivity and flexibility That has increased the capacity utilisation level compared to the previous system The DTPS G2 offline programming system makes it possible to convert the programs of the older robots for the new robot system Also new products can be programmed offline and are easy to transfer or copy to other work stationsMarko achieves 80 of its turnover with school furniture and sets out to compete with its products mainly on quality With this strategy the company has succeeded in gaining a leading market position in the Benelux region wwwmarkoinfo

To overcome language barriers between French-speaking clients and the Dutch Valk Welding organi-sation telephone calls from France are first put directly through to our French-speaking office worker Fabrice Lefegravevre The need to communicate in French with the Dutch head office of Valk Welding had come about owing to the growth in the number of Fre-nch-speaking clients and the exten-sion of the sales activities caused by the incorporation of Valk Welding France Atlantique

Fabrice Lefegravevre is a Frenchman who has lived for more than 25 years in the Netherlands and has worked at Valk Welding in Alblasserdam since February of this

year Fabrice has a technical background in the bodywork sector and has broad know-ledge of welding technology which ideally places him to give clients an optimum service for both technical and administra-tive issues He thus forms the pivot between French-speaking clients and the Dutch Valk Welding organisation and supports the field service staff of Valk Welding France and Valk Welding France Atlantique

Fabrice Lefegravevre pivot between French clients and the Valk Welding organisation

Video ArchiveWant to see how it works Watch the videos of current robot projects atwwwvalkweldingczvideos

Page 7: 2009-01-Valk Mailing-EN

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The company Faymonville the Bene-lux regionrsquos biggest manufacturer of semi-trailers for special transport has equipped all of its production units with Panasonic manual welding power sources Valk Welding has supplied the company with 250 manual welding machines over the past two years Faymonville uses these manual wel-ding power sources to completely weld heavy structural sections with lengths up to 18 metres The manual welding stations at Faymonville are also equip-ped with Wire Wizard welding wire feed systems in order to smoothly bridge the distance between the wel-

ding power source and the wire drive unit which in some cases exceeds a length of 12 metres

Faymonville has entered into a service contract with Valk Welding under which a unit price per year is paid for service and maintenance and the replacement of com-ponents This service contract has been taken out for a 10-year period after which it can be renewed for 2-year periods for each welding power source This service contract makes it possible for Faymonville to schedule the maintenance and overhaul costs for all of the organisationrsquos welding equipment Faymon-ville employs some 640 people Faymonville is now also using 4 welding robot systems wwwfaymonvillecom

Faymonville installs Panasonic manual welding machines throughout organisation

Valk Welding has recently supplied a combined arcstud welding system to the VDL Group The system is used to weld products for the car indus-try Products for this sector must be delivered absolutely free of defects The attachment of components using the stud welding method therefore has to be carried out fully automatically at all times To be completely certain that these studs have actually been attached the studs are welded onto the product by the robot

To have the arc welding and the stud welding carried out fully automatically with a single

robot the Panasonic arc welding robot is equipped with a Schunk tool changer That makes it possible for the robot to alternative fully automatically between the standard arc welding torch and the stud welding torch of Thomas Welding The stud welding head is equipped with a fully automatic feed that po-sitions the studs in the head The application of this special combination is the result of years of successful partnership between the VDL Group and Valk Welding and has led to a high degree of automation in several welding processes This system is the seventh arc welding robot that Valk Welding has installed within the VDL Group

See the video at wwwvalkweldingczvideosvideo_en_6html

Combined arcstud welding robot for VDL

Bollegraaf Recycling Machinery manufactu-res products including bale presses for waste paper and systems for processing industrial and domestic waste

Colophon

lsquoValk Mailingrsquo is a twice-yearly publication of Valk Welding BV and is sent free to all business relations If you want to receive this publication

in the future please send an email to infovalkweldingcom

The NetherlandsValk Welding BV

Staalindustrieweg 15PO Box 60

2950 AB AlblasserdamTel +31 78 69 170 11Fax +31 78 69 195 15

infovalkweldingcomwwwvalkweldingcom

BelgiumTel +32 (0)3 685 14 77Fax +32 (0)3 685 12 33

France Valk Welding France

Tel +33 (0)3 20 10 00 39Fax +33 (0)3 20 10 01 12

DenmarkValk Welding DK AS Tel +45 64421201Fax +45 64421202

Czech RepublicValk Welding CZ sro

Tel +420 556 73 0954Fax +420 556 73 1680

ProductionSteenkist Communicatie NL-Haarlem

steencomtiscalinl

PhotographyValk Welding BV

Erik Steenkist Marko bv Bollegraaf

Trade Fairs and Events

Vision amp Robotics Nieuwegein The Netherlands

16-17 June 2009

Schweissen und Schneiden Essen Germany

14-19 September 2009

Eurowelding ndash MSV 2009 Brno Czech Republic

14-18 September 2009

Metavak Gorinchem The Netherlands

10-12 November 2009

-

Marko installs fourth genera-tion welding robot system In spring of this year furniture produ-cer Marko BV put a new advanced welding robot system into operation at its production facility in Veendam The welding robot system represents the companyrsquos fourth generation of welding robots Marko was leading the way in the robotised welding of steel office and school furniture as far back as in the nineteen-eighties The investment in a Panasonic Tawers welding robot on a longitudinal movement and with 8 work stations has provided Marko with the last word in welding robot technology Marko is thus setting out to guaran-tee its product quality and production efficiency in the years to come

Higher capacity utilisation levelThe ample number of work stations makes it possible to limit the number of tool changes which leads to increased in productivity and flexibility That has increased the capacity utilisation level compared to the previous system The DTPS G2 offline programming system makes it possible to convert the programs of the older robots for the new robot system Also new products can be programmed offline and are easy to transfer or copy to other work stationsMarko achieves 80 of its turnover with school furniture and sets out to compete with its products mainly on quality With this strategy the company has succeeded in gaining a leading market position in the Benelux region wwwmarkoinfo

To overcome language barriers between French-speaking clients and the Dutch Valk Welding organi-sation telephone calls from France are first put directly through to our French-speaking office worker Fabrice Lefegravevre The need to communicate in French with the Dutch head office of Valk Welding had come about owing to the growth in the number of Fre-nch-speaking clients and the exten-sion of the sales activities caused by the incorporation of Valk Welding France Atlantique

Fabrice Lefegravevre is a Frenchman who has lived for more than 25 years in the Netherlands and has worked at Valk Welding in Alblasserdam since February of this

year Fabrice has a technical background in the bodywork sector and has broad know-ledge of welding technology which ideally places him to give clients an optimum service for both technical and administra-tive issues He thus forms the pivot between French-speaking clients and the Dutch Valk Welding organisation and supports the field service staff of Valk Welding France and Valk Welding France Atlantique

Fabrice Lefegravevre pivot between French clients and the Valk Welding organisation

Video ArchiveWant to see how it works Watch the videos of current robot projects atwwwvalkweldingczvideos

Page 8: 2009-01-Valk Mailing-EN

Colophon

lsquoValk Mailingrsquo is a twice-yearly publication of Valk Welding BV and is sent free to all business relations If you want to receive this publication

in the future please send an email to infovalkweldingcom

The NetherlandsValk Welding BV

Staalindustrieweg 15PO Box 60

2950 AB AlblasserdamTel +31 78 69 170 11Fax +31 78 69 195 15

infovalkweldingcomwwwvalkweldingcom

BelgiumTel +32 (0)3 685 14 77Fax +32 (0)3 685 12 33

France Valk Welding France

Tel +33 (0)3 20 10 00 39Fax +33 (0)3 20 10 01 12

DenmarkValk Welding DK AS Tel +45 64421201Fax +45 64421202

Czech RepublicValk Welding CZ sro

Tel +420 556 73 0954Fax +420 556 73 1680

ProductionSteenkist Communicatie NL-Haarlem

steencomtiscalinl

PhotographyValk Welding BV

Erik Steenkist Marko bv Bollegraaf

Trade Fairs and Events

Vision amp Robotics Nieuwegein The Netherlands

16-17 June 2009

Schweissen und Schneiden Essen Germany

14-19 September 2009

Eurowelding ndash MSV 2009 Brno Czech Republic

14-18 September 2009

Metavak Gorinchem The Netherlands

10-12 November 2009

-

Marko installs fourth genera-tion welding robot system In spring of this year furniture produ-cer Marko BV put a new advanced welding robot system into operation at its production facility in Veendam The welding robot system represents the companyrsquos fourth generation of welding robots Marko was leading the way in the robotised welding of steel office and school furniture as far back as in the nineteen-eighties The investment in a Panasonic Tawers welding robot on a longitudinal movement and with 8 work stations has provided Marko with the last word in welding robot technology Marko is thus setting out to guaran-tee its product quality and production efficiency in the years to come

Higher capacity utilisation levelThe ample number of work stations makes it possible to limit the number of tool changes which leads to increased in productivity and flexibility That has increased the capacity utilisation level compared to the previous system The DTPS G2 offline programming system makes it possible to convert the programs of the older robots for the new robot system Also new products can be programmed offline and are easy to transfer or copy to other work stationsMarko achieves 80 of its turnover with school furniture and sets out to compete with its products mainly on quality With this strategy the company has succeeded in gaining a leading market position in the Benelux region wwwmarkoinfo

To overcome language barriers between French-speaking clients and the Dutch Valk Welding organi-sation telephone calls from France are first put directly through to our French-speaking office worker Fabrice Lefegravevre The need to communicate in French with the Dutch head office of Valk Welding had come about owing to the growth in the number of Fre-nch-speaking clients and the exten-sion of the sales activities caused by the incorporation of Valk Welding France Atlantique

Fabrice Lefegravevre is a Frenchman who has lived for more than 25 years in the Netherlands and has worked at Valk Welding in Alblasserdam since February of this

year Fabrice has a technical background in the bodywork sector and has broad know-ledge of welding technology which ideally places him to give clients an optimum service for both technical and administra-tive issues He thus forms the pivot between French-speaking clients and the Dutch Valk Welding organisation and supports the field service staff of Valk Welding France and Valk Welding France Atlantique

Fabrice Lefegravevre pivot between French clients and the Valk Welding organisation

Video ArchiveWant to see how it works Watch the videos of current robot projects atwwwvalkweldingczvideos