Overview
Safety Equipment Fabrication Challenges
Safety Link is a manufacturer of innovative fall protection and working-at-heights safety equipment based in Maitland, NSW. Their products are specified and trusted on worksites where safety is critical.
SafetyLink required a robotic welding solution capable of producing consistently high-quality welds across large steel and aluminium assemblies while meeting the structural and appearance requirements of safety-critical products.
Selecting the right automation partner was equally important. SafetyLink needed more than world-class equipment—it required responsive local support, practical training and the capability to support the system over its full operating life. This combination was essential to achieving long-term reliability, developing in-house capability and providing a scalable foundation for future growth.
The Challenges
Enhancing Speed, Consistency, and Capabilities
Safety Link encountered several obstacles that threatened their production capabilities:
Better Use of Skilled Tradespeople
Repetitive production welding occupied skilled welders who could be better utilised on more complex fabrication and welding tasks requiring their experience and judgement.
Dual Capabilities
They needed a solution to weld both steel and aluminium effectively with the same robot.
Appearance-Critical Welds
Safety equipment required clean, cosmetic and consistent welds across batches.
Specification-Critical Welds
Maintaining high-quality welds for specification-critical safety equipment.
Safety Link needed a solution that addressed all of these concerns simultaneously, across a diverse product range, without creating a system so complex it became difficult to operate.
The Solution
Precision, Speed and Scale
Infinite Robotics supplied an Australian Made dual-station industrial robot welding system to solve these challenges. This system was designed to offer advanced capabilities for welding thin aluminium components with superior control and precision.
FANUC ArcMate 120iD/12L Robot
A proven industrial robot from the world’s largest robotics manufacturer, backed by local support and training to provide confidence that the system will perform reliably, day in and day out.
Fronius CMT System
A 500-amp, water-cooled welding package designed for demanding production applications and extended welding cycles. Fronius Cold Metal Transfer technology provides precise arc control and reduced heat input, making it particularly effective for welding thin aluminium components.
High-Capacity Positioners
This system is designed to handle parts up to 3,800mm long and 1,500mm wide and weighing up to 1,500kg.
Dual Workstations
Allows operators to load and unload parts on one side while the robot welds on the other, maximising productivity.
Controlled Heat Input
Advanced welding processes minimise heat input and distortion, producing clean, cosmetically consistent welds on thin materials.
Torch Cleaning Station
Automatically cleans spatter build-up from the torch nozzle, allowing for continued operation.
Improved Safety
Perimeter fencing, interlocked safety devices and on-torch fume extraction help protect operators from robot movement, welding hazards and airborne contaminants.
This turnkey solution was developed to address current concerns while also preparing them for future growth.
Key Features & Capabilities
Productivity Meets Safety
The dual-station welding system delivered various benefits for Safety Link, including:
Clean, Cosmetic Aluminium Welds
The automated system ensured flawless finishes for appearance-sensitive equipment.
High Repeatability
Delivers consistently high-quality welds across a wide range of component sizes and batches.
Reduced Distortion
The low-heat input process minimises warping, even on thin materials.
Large Part Capabilities
This system is designed to handle large fall protection assemblies and safety equipment.
Implementation
Smooth Transition to Modern Automation
Infinite Robotics delivered the system as a turnkey solution, allowing for minimal disruptions to operations. The implementation process included:
Installation and Commissioning
The robotic system was installed in the client’s facility and fully operational in a short timeframe.
Comprehensive Training
Operators received hands-on training to put the team in control of the system quickly and confidently.
This straightforward, user-friendly design allows operators to achieve high-quality results and streamlined productivity from day one.
The Results
Faster, Cleaner, Safer Production
The robotic welding system delivered extraordinary results that addressed Safety Link’s challenges:
Reduced Cycle Times
This dual system significantly reduced welding time compared to manual welding, increasing productivity.
Improved Weld Consistency
The automated system delivered consistently flawless weld quality and finishes across batches.
Complete Safety
Advanced safety features enhanced safety, reducing manual handling of repetitive tasks and exposure to harmful welding fumes.
This system not only addressed Safety Link’s immediate challenges, but also delivered a future-ready solution to help them achieve long-term success.
Suitable Applications
Versatile Solution for Diverse Fabrication
The dual-station industrial robot welding system is well-suited to any production environment requiring clean welds, large component capacity, and multi-material capability, including:
Ute Trays and Toolboxes
Perfect for large, appearance-critical aluminium components.
Aluminium Frames
Ensures clean, consistent welds for structural integrity.
Sheet-Metal Products
Designed for visual-quality welds with minimal distortion.
Whether you’re producing aesthetic products or specification-critical safety equipment, this robotic welding system delivers the consistency and efficiency you need to stay ahead of the competition.
Ready to Automate Your Welding Process?
Contact Infinite Robotics today to learn how our tailor-made robotic welding solutions can transform your operations and help you achieve your goals.