Robotic Welding System for Welding Large, Heavy Parts

A prominent manufacturer in the heavy agricultural machinery industry was looking to improve productivity and safety in welding large, heavy parts. These parts, weighing up to 2,500kg each, required welding on multiple planes while maintaining the correct welding position. With dimensions reaching up to 8m in length and 2m in width, along with the need for multi-pass welding at high amperage on thick plates, it was challenging to maintain optimal comfort and ease during the welding process. 

KEY CHALLENGES

Handling Heavy Parts: Manual welding of parts weighing up to 2,500kg posed ergonomic challenges and increased the risk of worker injuries. 

Complex Welding Geometry: Parts with welding on multiple planes required precise positioning and orientation to ensure consistent weld quality. 

Limited Reach and Accessibility: The sheer size and dimensions of the parts can make it difficult to access certain weld joints with a robot, leading to compromised weld quality and productivity. 

To address the unique challenges faced by our client, our team proposed a comprehensive solution centered around the integration of advanced robotic welding technology tailored specifically for welding large, heavy parts. 

SOLUTION HIGHLIGHTS

• Long-Reach Robotic Arm: We deployed the long reach Fanuc ArcMate M710iC/12L robot allowing it to access and weld large parts with ease. 

• Versatile Positioning System: A 2-axis skyhook was employed, enabling the part to be orientated in three planes for optimal positioning on complex parts. This ensured precise alignment and consistent weld quality across all planes. A 2T headstock was utilised in the second station for welding longer and wider parts. 

• Extended Reach with Track Mounting: To accommodate the large size of the parts and achieve better positioning for awkward welds, the robotic welding system was mounted on a track, extending its reach and flexibility. 

• High-Performance Welding System: The Fronius TPS 500 welding system was selected for its advanced capabilities ensuring superior weld quality and productivity. 

RESULTS

Enhanced Productivity: The integration of the robotic welding system significantly improved productivity by automating the welding process, reducing cycle times, and minimising downtime associated with manual handling and repositioning of parts. 

Improved Weld Efficiency: With precise positioning and multi-pass welding capabilities, the robotic system delivered consistent weld quality across all planes, ensuring the structural integrity and durability of the welded parts. 

Worker Safety: By eliminating the need for manual handling of heavy parts and reducing exposure to high amperage welding processes and fumes, the robotic welding system improved worker safety and minimised the risk of workplace injuries. 

Our innovative solution for welding large, heavy parts demonstrates our commitment to leveraging advanced robotics technology to address the unique challenges faced by our clients in the heavy machinery industry. By streamlining the welding process, enhancing productivity, and ensuring superior weld quality, we have empowered our client to stay competitive and achieve excellence in their manufacturing operations.