Bellsonica India Co.,Ltd
Welding Power Source Integrated Robot TAWERS (AWP4)
Achieving Advanced Automation! Enhance Productivity and Create a Comfortable Workplace with S-AWP.
Introduction: 2017 Location: Ibaraki
Issue
・Reduce defects when welding thin plates (1 mm or less)
・Achieving highly consistent welding quality
Solution
We introduced Panasonic’s welding robot, Active TAWERS 4. Welding defects such as burn-through and spatter adhesion decreased, and welding quality improved.
"Panasonic responds quickly to issues, as they do in Japan. Their local team in India also provides extensive support for welding parameters and other matters, which is very helpful."
Background
Growing customer demand for quality and consistency in welding quality
“Customers expect the same or even better product quality than what is delivered in Japan. Providing high quality and on-time delivery has become the industry standard, just as it is in Japan.”
(Hideyuki Tsuchiya, Assistant General Manager)
“Welding quality had been improving, but because we are handling an increasing variety of components (different materials and plate thicknesses), we needed to create an environment capable of accommodating various products.”
(Amit Sharma, Senior Manager)
Initiatives for Creating a Comfortable Factory
Securing skilled welders is a challenge, but so is attracting younger workers. To change the dark image commonly associated with factories, STN has undertaken various initiatives. Rather than simple labor-saving, creating a workplace where employees can work with a smile and improving individual productivity was one of their goals.
Reason for Introducing the Welding Robot System
Maintaining welding quality in various material applications
“We made daily adjustments to welding parameters, equipment design, shielding gas flow, and wire cast, but we were unable to reduce in-process defects. Therefore, we introduced Active TAWERS 4 to stabilize welding quality.
(Hideyuki Tsuchiya, Assistant General Manager)
Resolving quality issues when welding thin plates
“We aimed to improve quality when welding thin plates. The immediate challenges were maintaining appropriate penetration and reducing reliance on manual welding machines (semi-automatic welding machines).”
(Amit Sharma, Senior Manager)
Checking product quality on the worksite
Results After Introducing the Welding Robot
Consistent quality in thin-plate welding
“Introducing Active TAWERS 4 resulted in fewer in-process defects than before. I believe the welding control and other functions of Panasonic’s welding robot allow us to set welding parameters more easily and have helped stabilize welding quality.”
(Hideyuki Tsuchiya, Assistant General Manager)
The importance of ease of use and on-site support
“The teach pendant is user-friendly and straightforward to operate, so teaching employees how to use it is also easy. Additionally, Panasonic India provides prompt support, so even if a problem occurs, we can minimize downtime.”
(Amit Sharma, Senior Manager)
Customer Comments
A partner that has enabled us to realize stable, high-quality production
“We chose Panasonic for high-quality welding. We have also adopted Panasonic's robot systems in various factories (Japan, Indonesia), with the aim of delivering consistent quality locally.
We intend to continue building a good partnership with Panasonic so that we can offer suppliers, our customers, the same or even better quality than in Japan, along with the value Bellsonica provides.”
Further on-site improvements can be anticipated
“By introducing Panasonic’s robot system, we were able to improve consistency in welding quality, reduce defects, shorten cycle times, and reduce labor costs. I feel we have a competitive advantage over our rivals. We also recognize that operability and Panasonic’s support system are outstanding, and contribute to on-site training and reductions in downtime.”
Customer Information
Bellsonica Auto Component India Pvt. Ltd.
Bellsonica Auto Component India Pvt. Ltd. (Bellsonica India) designs, develops, and produces components for the automotive industry. The company has improved productivity and quality through a high-precision robot system, its own welding control technology, and comprehensive on-site support. With implementation training and maintenance systems in place, the company’s strengths lie in flexibly responding to meet diverse customer needs.
Related equipment and services
Active TAWERS 4, a welding power source integrated robot system
A high-efficiency welding robot system that achieves low spatter and high-speed welding
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