Based on the modular system of the Genius product family, the new KUKA Genius D double-head friction welding machine is the ideal solution for applications with double welds. Available as KUKA Genius D power, it makes for maximum efficiency, allowing simultaneous welding of the component at both ends in a single work cycle (one-pass productivity). Industries & applications The KUKA Genius D features the latest, industry-proven technology modules and, with a forge force of 1.2 - 30 tonnes, can be used for a wide range of components in diverse industries, e.g.: • Automotive - Camshafts - Drive / prop shafts - Axles • Construction industry - Truck axles - Piston rods - Hydraulic cylinders • Metal industry - Shafts - Heat exchangers - Tools System architecture The newly designed system architecture enables a highly compact configuration (22 m2). The two large operator doors allow fast set-up, loading and unloading optimized in terms of cycle time, and ergonomic working. Similarly, the higher machine performance, ease of transportation (container dimensions), optimized cabling, reduced footprint and shorter commissioning time significantly enhance the cost efficiency of the Genius D. The electronically controlled hydraulic system additionally saves up to 20 % energy. Features & functions Numerous functions can be individually configured: • Automatically adjustable backstop (ABS) • Defined-angle positioning • Component lifter • Automatic operator door • User management with EKS chip • Weld data export • Data matrix code interface (for component tracking) • Ready for I4.0, based on OPC UA • Automation interface • KUKA RemoteService Control & operation The KUKA Genius D has a clearly designed touch panel for simple and intuitive operation. Comprehensive reporting with data analysis of all process-relevant parameters for improved quality monitoring is possible for 12 weld parameters in real time thanks to the new PCD controller. A reject is reported if the parameter limits are violated.

Joining Solutions�KUKA Genius D Basic configuration – technical data Forge force* Spindle speed* Spindle drive Slide advance Adjustable travel, ABS system Component length (spindle side)* Component length (center)* Noise emission Footprint Dimensions (L × W × H, excl. swarf conveyor) Weight * Depending on component type, forge force and process sequence ** Double-head operation *** Single-head operation **** Double-head operation with turning Wide range of options Optional packages are available for the Genius D. These significantly help to increase productivity and can be configured independently...