AKG Group relies on high-tech automation by CLOOS

Sarreguemines/Haiger –The AKG Group relies on high-tech automation from CLOOS to weld aluminum components at its French site in Sarreguemines. The specialists for heat exchangers and cooling systems use two CLOOS robot systems and numerous manual welding machines in their production. "With the two robot systems, we have significantly increased our productivity," explains Sacha Jung, Managing Director of AKG France. "By using the welding fume extraction torch and the laser sensor on the new robot system, we have been able to achieve considerable energy savings and improved working conditions."

For more than 100 years, the AKG Group has been developing and producing high-performance heat exchangers and complete cooling modules and systems for construction machinery, compressed air systems, industrial coolers, agricultural and forestry machinery, vehicle construction, rail vehicles, aviation, municipal vehicles, household appliances and special applications. More than 3,500 employees produce over 2.5 million heat exchangers in various designs every year. In addition to the French site, there are 10 other independent production sites and 14 sales companies around the world. As a leading global provider of customer-oriented system solutions, the AKG Group is committed to the highest quality standards. This is why AKG relies on automated welding solutions from CLOOS.

High-tech robot system increases productivity
The company commissioned the first robot system at the French production site back in 2015. Last year, another robot system with high-tech automation components followed.
The heart of the system is the QIROX QRC-350-E robot.  The wide range of the 7-axis robot simplifies and speeds up the welding of complex workpieces. The C-shaped frame positions the robot overhead on a fixed extension arm. This robot position enables a better accessibility to the workpiece and facilitates welding of bigger workpieces.  
The C-frame is mounted on the floor or a floor-mounted linear track which moves the robot in horizontal direction. The new robot system consists of two stations that can be used flexibly for different components. Due to the 2-station principle of the robot system, it is possible to insert the components in one station while the robot is welding in the other station – an enormous saving of time in the whole process run. "With the new robot system, we were able to significantly reduce cycle times compared to manual welding," says Alex Reiff, Head of Welding Production.

Torch-integrated fume extraction
The new system is equipped with a torch-integrated fume extraction which offers a safe and effective extraction of welding fumes directly at the source. Up to 95 percent of the fume is eliminated directly during welding at the point of origin near the arc. With the first robot system, AKG still had to invest in an extensive extraction system with curtains, complex pipe systems and a large filter unit to extract and clean the polluted air. When extracting directly at the welding torch, the volume of polluted air is much smaller now. By using the extraction welding torch system, AKG has to invest significantly less in extraction technology, air ducting system and filter device – with the same effect. A flexible hose with a small diameter replaces the complex pipe system for discharging the contaminated air to the filter unit. Due to the smaller volume of contaminated air, a smaller filter unit is necessary. Another advantage: Due to the optimised energy efficiency as well as the minimised effort for cleaning and replacement of the filter components, the operating costs are considerably reduced.
AKG was also able to significantly simplify and speed up the entire production process thanks to the torch-integrated fume extraction. While the first system had to be laboriously loaded by hand, a crane solution can be used for loading and unloading in the new system due to the space saved.

This is particularly appreciated by the production staff. "For me, the biggest advantage of the new system is the direct extraction at the welding point," explains system operator Mickaël Thielges. "This means there is more space above to carry out the various transport tasks with the overhead crane."  Last but not least, the employees benefit from the clean air and the better working environment thanks to the direct fume extraction.