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Magna System Chassis in France is using Burkert’s robotic welding cooling system in the production of chassis parts for MCC Smart, a daughter company of Daimler-Benz.

Magna International designs, engineers, and manufactures most of the components used to build motor vehicles.

Fabrice Dumontier, assistant general manager of Magna System Chassis, was the engineer responsible for the testing programme that resulted in the company-wide adoption of Burkert’s system.

’Burkert cooling systems have proven to be very reliable and are efficient in detecting the loss of an electrode,’ he said.

’Magna has been operating assembly lines at Hambach since 1998.

’The cooling systems that were originally fitted to our welding robots were not reliable and were difficult to regulate.

’We therefore instigated a test programme to find the best cooling system.

’After many tests, we finally chose the Burkert system; the first project using 100 per cent Burkert equipment began in 2003,’ Dumontier added.

Since January 2007, 160 Burkert cooling systems have been installed on Magna assembly lines.

Magna now instructs systems integrators to schedule Burkert systems on all welding equipment supplied to the Hambach plant.

Dr Egon Huefner, head of Burkert’s segment-management team for welding cooling systems, said: ’The same benefits that Magna is enjoying from our system are applicable across all car plants, because of their dependency on robotic welding systems.

’The problem with automated body welding robots is that they generate large amounts of heat, necessitating liquid cooling of the welding tips.

’If a tip becomes damaged in the welding process, it can come off, leaving the cooling circuit open.

’This can result in unacceptable welds as the robot continues; and, potentially, three types of downtime: firstly, as cooling fluid is mopped up – glycol does not evaporate; secondly as the tip is replaced; and thirdly as the machine is reset.

’Our intelligent cooling system overcomes all of these problems.

’It detects pressure drop, due to welding-tip cap loss, and automatically shuts off water, reducing contamination, downtime and scrap,’ Huefner concluded.

Burkert’s solution to welding-tip failure is based upon a design that employs an optical paddlewheel to detect the water flow-rate returning from the robot.

If the flow rate falls below a set point, an alarm triggers the robot controller to stop.

When this signal is given, the cooling system valves close to isolate the feed and return water pipes.

In addition to preventing downtime and contamination, this design offers further advantages, in that the optical paddlewheel is not affected by the temperature of the water; it is also non-magnetic and is not affected by ferrous particles in the water.

In addition, the cooling-system unit can be pre-calibrated before fitting and provides clear displays of actual system flow rates and alarm set-points, providing transparency and flexibility in operation for the user.

Burkert Fluid Control Systems

Burkert Fluid Control Systems has been manufacturing products and systems for over 60 years that can be used wherever fluid media and gases need to be measured, controlled and regulated.

Burkert Fluid Control Systems has been manufacturing products and systems for over 60 years that can be used wherever fluid media and gases need to be measured, controlled and regulated.Whether the application is filling, level, flow, pressure or temperature we have a solution and a uniquely comprehensive range of products to handle it, including solenoid, process and analytical valves, pneumatic actuation, sensors and controllers.

For Burkert it is not enough to simply offer individual products.Our aim is to provide complete system and application solutions that meet the specific needs of our customers.Tell us what you need and our engineers will find an appropriate solution using our vast experience and a wide range of services such as advice and engineering, installation, testing, and after-sales support.

Burkert’s global presence offers our customers an additional advantage.Products and systems are constantly developed and optimised according to international standards.Through this process synergy effects evolve which ensure technological leadership and competitive advantage

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