In close collaboration with leading vehicle manufacturers, the developers and product managers of ABICOR BINZEL ROBOTIC SYSTEMS have analysed the special requirements for laser soldering and welding applications in vehicle construction in order to create a wire feeder system that is coordinated optimally to the high demands of each production environment. The result is the MFS-V3 wire feeder system (third generation master feeder system) with a completely newly developed eBOX. With its modern and precisely matched components, the eBOX is exactly equipped for the constantly increasing requirements profi le for laser applications, in particular in vehicle manufacturing around the world.

For example, a wide-range input or the multivoltage connection for supply voltage (can be used worldwide) or a modular mainboard, which allows to operate different types of motor, e.g. different sizes and outputs, or even servomotors.

In addition, the AIDA eBOXes (AutomatisierungsInitiative Deutscher Automobilhersteller – Automation initiative of German car manufacturers / ) have safety relays to make it possible to feed wire in for service work after a drop in voltage
by actuating the central key switch.

Another advantage of the new development is an even more exact and precise digital wire feeding through a fast 32-bit controller, which minimises inprocess response times. Optimised maintenance and service interfaces (SD card) for user-friendly operations characterise the new overall system MFS-V3.

Adaptable and user-friendly operating / service software

Appropriately for the new eBOX, the operating/service software was radically redeveloped and now comprises very extensive process monitoring and many parameters that can be varied in dependence on the application, including simplified visualisation, documentation of the processes and a fault memory with a plain text display.

Two operation modes can now be differentiated for monitoring with control or observation, for example of the actual wire speed and of the motor current: direct operation mode and job operation mode. In the direct operation mode, all parameters are set by the higherlevel controller, and in job operation mode the parameters can simply be set in the operating /service software and stored in the eBOX. In this case, the individual jobs are only selected by the higher-level controller. This saves valuable bus transmission time and increases the cycle frequency of the overall system. In addition, there are numerous additional setting possibilities and options that can be adjusted individually to the application, such as, for example, hot wire function, wire end sensor or wire retraction.

The operator-friendly user interface of the service software can be operated not only through the system PC but also by means of a control panel (MF Control) from ABICOR BINZEL ROBOTIC SYSTEMS. The relevant settings are easy to access and can be controlled intuitively.

After presetting, maintenance intervals are outputted either directly in the operating / service software or per bus message, so that downtimes are avoided and reliable production is guaranteed. A wire buffer function was integrated to make the process even more secure with wire feeding, increase the quality of the laser seams, reduce the acceleration time and prepare the system optimally for the next application. Here, the wire is fed through the rear drive into the MasterLiner after each feed cycle. This can be set to a limited extent and, again, application-specific, in the operating / service software via the intake current of the rear drive. The wire buffer function guarantees that there is always sufficient wire in the MasterLiner and that friction during wire feeding is reduced to a minimum. The system profits here from the independent activation (separate control loops) of the two drives. With medium and short feed distances, the process can be operated with just one drive (front drive). Operators then profit from the cost reductions that result from saving the second drive.