Overview
Tackling Automotive Welding Challenges
ATD Customs in Crows Nest, QLD, builds high-end bull bars and accessories for Toyota LandCruisers and Ford Ranger Super Duty utes. Their reputation rests on their workmanship and high attention to detail, delivering only the best solutions built to the standards that serious 4WD owners demand.
As demands increased, they started to have concerns over whether they could continue to keep up with demand without sacrificing quality. For over four years, ATD Customs searched for a robotic welding partner capable of meeting that standard and solving their productivity requirements. Infinite Robotics were the only ones capable of answering their questions and providing the solution they needed to complement their experienced team and allow them to weld more parts to their proven quality and exacting standards.
The Challenges
Barriers to Productivity and Consistency
Automotive components are complex, and the welds need to meet both appearance and structural specifications. ATD Customs encountered several challenges that made it difficult to maintain the standards and output they were accustomed to:
Complex Welds
Precision welding was essential for cosmetic and specification-critical welds.
Repetitive Work
Repeated welding tasks occupied valuable tradespeople who could be better utilised on specialised fabrication, fit-up and other high-value work.
High-Mix Production
The variety of components and relatively low production volumes required a flexible solution that could be quickly adapted without compromising ATD Customs’ established workmanship standards.
The Solution
Flexible, Precision Welding for Complex Automotive Components
Infinite Robotics delivered an Australian-Made FlexWeld dual-station cobot welding system to work alongside their team and solve these challenges. The system featured a FANUC CRX30iA collaborative robot integrated with a Fronius welding system to provide advanced capabilities for welding with superior control and precision.
FANUC CRX30iA Collaborative Robot
Handles high-payload up to 30kg with impressive reach up to 1,889mm, and an 8 year maintenance-free guarantee.
Fronius Welding System
500amp, water-cooled system to support longer welds and a long cobot lifespan.
Dual Workstations
Allows operators to load and unload parts from one station while the robot continues to work on the other, achieving maximum productivity.
2-Axis Integrated Welding Positioner
Enables full rotation and coordinated motion to rotate the parts while welding for full welding access.
Tablet Teach Pendant Programming
Enables simple drag and drop operation through a smart tablet.
We supplied the cobot, positioner and welding system and then ATD Customs opted to build the cell themselves using their advanced expertise from building quality bullbars.
Key Features & Capabilities
Precision Meets Productivity
The cobot welding system delivered various benefits for the client, including:
Reliable Productivity
The system efficiently and effectively delivers flawless finishes for low-volume, high-mix production
High Repeatability
Consistent quality across complex, cosmetic and specification-critical welds.
Fast Programming
User-friendly interface allows operators to achieve quality results from day one.
Accurate Multi-Plane Welding
The 2-axis positioner provided full rotational access to ensure consistent welds on complex bullbars and automotive accessories.
Implementation
A Seamless Transition to Welding Automation
Infinite Robotics delivered the cobot system as a turnkey solution, allowing for minimal disruptions to operations. The implementation process included:
Installation and Commissioning
The system was installed and fully operational in a short timeframe.
Comprehensive Training
Operators received hands-on training to quickly adapt to the new system and maximise its capabilities.
The simple design and user-friendly programming allowed ATD Customs’ team to achieve high-quality results from day one. As a testament to this, the customer programmed three welds all with excellent results on the first day after training.
The Results
Enhanced Productivity and Consistency without Increasing Headcount
After installing the FlexWeld dual-station cobot welding system, ATD Customs experienced impressive results:
Enhanced Weld Consistency
The cobot system delivered repeatable, high-quality results every time.
Faster Turnaround
The automated dual-station cobot enabled faster production without increasing headcount.
Improved Weld Quality
The advanced system delivered precise, reliable welds across all products.
These improvements not only addressed ATD Customs’ immediate challenges but also set them up for long-term growth and success.
Suitable Applications
Versatility in High-Mix Fabrication
The FlexWeld dual-station cobot welding system is ideal for a wide range of applications, including:
Automotive Components
Perfect for high-strength and cosmetic 4WD bullbars and other accessories.
Defence Equipment
Designed for high performance specification-critical welds.
Mining Machinery
Ideal for heavy assemblies and robust welds.
High-Mix Fabrication
Perfectly handles low-volume, high-mix production.
General Manufacturing
Delivers reliable results for various component types.
Whether you’re fabricating automotive parts or other heavy-duty components, this cobot system delivers the consistency, precision, and efficiency you need to remain competitive.
Ready to Automate Your Welding Process?
Contact Infinite Robotics today to learn how our custom solutions can transform your operations and help you achieve your goals.