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KUKA Robot Guide
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KUKA Picus 2

With 8-20 kN forge force, the fully automated single-head friction welding machine is the smallest modular machine in the machine portfolio and stands out due to its top performance as well as a diverse range of components thanks to the integrated handling robot.

Highly productive and versatile

The standardized, fully automated friction welding machine KUKA Picus 2 offers innovations for small-scale parts. This new machine generation, as successor to the customized KUKA RS 2, has a modular design and is a true all-round solution for various friction welding processes. In addition to the welding of valves for internal combustion engines, the field of application extends beyond the automotive industry to new applications in e-mobility and general industry. Picus 2 offers outstanding economic efficiency and maximum versatility through integrated robotic automation.

 

Wide variety of applications

Automotive industry

Small high-performance components for internal combustion engines:

  • Solid valves
  • Sodium-filled hollow valves

E-mobility

High-quality aluminum-copper mixed joints endowed with optimum conductivity through the KUKA short-cycle friction welding process:

  • High-voltage cables 12V
  • High-voltage cables 48V
  • Connectors / connecting elements

General industry

Various small components with rotationally symmetrical design for a wide range of applications:

  • Drive shafts
  • Threaded rods
  • Guide and contact pins
  • Tools
  • Special screws

Convincing advantages of the KUKA Picus 2

  • Individuelle Komplettlösung

    Top performance

    • Fully automatic loading and unloading
    • Use of tried-and-tested technology modules such as the HNC process axis
  • Einfache Bedienung

    Simple and ergonomic operator control

    • Improved access thanks to new design
    • Lightweight operator doors & large workspace
    • Intuitive operator control via a touch panel with a state-of-the-art graphical user interface
  • Genauigkeit

    Flexibility due to handling robot

    • Enormous expansion of the component spectrum for a wide range of applications and industries
  • KUKA Summary

    Quality monitoring

    • Monitoring by KUKA PCD (Process Parameter Control and Documentation)
    • Reduction of downtime due to automatic offloading of rejected parts
  • Servicefreundlichkeit

    Improved component handling

    • Optimum integration into the production workflow
  • Einfache Installation

    Simple installation

    • Plug & play solution
    • Quick installation and relocation thanks to integration of the hydraulic power pack and control cabinet into the machine

  • Low space requirements

    • Compact machine with a footprint of just 4 m²

  • Industrie 4.0

    • Extensive sensors for monitoring the machine and the welding process
    • Availability of data via standardized interfaces for evaluation in the cloud 
    Industrie 4.0 SmartProduction

KUKA Picus 2 in detail: equipment, accessories 

  • User-friendly operator panel

    Touch screen operation with clearly structured menu navigation makes operation of the Picus 2 quick and intuitive. A digital operating manual with search function and maintenance schedule increases user friendliness.

  • Handling robot

    By adding greater flexibility, the integrated KUKA AGILUS robot can expand the component spectrum enormously and also paves the way for a wide range of new applications.

  • Material supply interface

    The material supply can be individually adapted via 

    • input conveyors
    • parts conveyors

     

    Material output is accomplished 

    • via a chute for good parts
    • automatically via the robot for reject parts
     

     

  • Transport-friendly design

    Plug & play – Integration of hydraulic and electrical equipment reduces the floor space requirement and simplifies transportation and installation.

     

  • Improved quality monitoring

    Latest KUKA PCD controller for reliable quality monitoring through validated parameters:

    • Storage of all parameters in the database
    • Comprehensive export of weld data
    • Detailed reporting and data analytics
    • Monitoring and documentation of all parameters (sampling rate 1 ms)

Further options for friction welding with Picus 2

  • Facing for component preparation
  • Removal of the weld flash by turning or punching
  • Component and customer-specific clamping tools
  • Sensitive process axis with 12 kN forge force
  • Active Travel Control (for minimizing length tolerances)
  • Automation with cell interface
  • OPC UA interface for I4.0

The new KUKA Picus 2 is a solid investment for the future, since it is versatile and based on the state-of-the-art control and process technology of the larger Genius product family.

Till Maier, Portfolio Manager for Advanced Welding Solutions

Perfect welding and easy handling thanks to innovative operation 

The intuitive user interface stands out through

Welding process

User-friendly configuration and setting of the welding process

Data backup

Input and backup of data via USB interface

Documentation

Documentation of the welding results by means of database, printer or PDF export

Parameter profiles

Graphical representation of current and archived parameter profiles

Control & monitoring

Control and monitoring of all parameters of the welding process in the millisecond range

Quality management

Full traceability via data matrix code. Weld data are assigned to the individual components.

Program management

Management of up to 1,000 welding programs

Presentation of values and status

Display of the actual values and parameters as well as the current status in plain text

Do you have further questions about the Picus 2 machine or desire a customized solution?

We are happy to provide support and advise you
Contact us now

Contract manufacturing in friction welding

We weld both individual parts and complete assemblies to order

Further machines and processes for welding metallic materials