Overview
Meeting the Challenges of Multi-Plane Welding
A manufacturer specialising in agricultural machinery faced significant challenges in welding large, heavy components. These parts required welds on all sides, necessitating multiple reorientations, which slowed production and posed safety risks. The company needed a solution to improve efficiency, quality, and safety while maintaining high production output.
The Challenges
Barriers to Efficiency and Quality
The manufacturer encountered several obstacles that impacted their operations:
Manual Repositioning
Slow and labour-intensive, manual flipping of large components presented safety risks.
Production Bottlenecks
Maintaining production output was difficult with time-consuming manual processes.
Inconsistent Weld Quality
Achieving consistent, full-penetration welds on long, high-amperage, multi-pass welds was a challenge.
To overcome these issues, the company required an advanced robotic welding solution capable of handling complex, multi-plane components with precision and efficiency.
The Solution
Precision Welding for Multi-Plane Components
Infinite Robotics delivered a custom Australian-made robotic welding system tailored to the customer’s needs. The solution included:
Track-Mounted FANUC ArcMate 120iD/12L Robot
A long-reach industrial robot capable of accessing all welds with flexibility.
2-Axis Welding Positioner
Ensured all welds were presented in the flat or horizontal position for optimal quality.
Fronius TPS/i 500A Water-Cooled Pulse MIG Welding System
Provided precise, high-amperage, multi-pass welds with improved joint penetration.
Key Features & Capabilities
Efficiency Meets Safety
The robotic welding system offered numerous benefits, including:
Complete Access to Multi-Plane Welds
The track-mounted robot and positioner ensured precise welds on all sides of the component.
Improved Joint Penetration
The advanced MIG system delivered strong, consistent welds with reduced rework.
Controlled Rotation
The positioner could rotate parts up to 1,600mm wide, 1,600mm high, and weighing up to 1,000kg, ensuring precise weld positioning.
Safer and Quicker Part Handling
Automation eliminated manual flipping, creating a safer and more efficient workflow.
Reduced Cycle Times
Faster, more consistent welding improved overall productivity.
Consistent Weld Quality
Delivered uniform, full-penetration welds across all components.
Implementation
A Smooth Transition to Automation
Infinite Robotics provided the system as a ready-to-use solution, ensuring minimal disruption to the customer’s 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 intuitive design and user-friendly programming allowed the customer’s team to achieve excellent results from day one.
The Results
Productivity and Quality Boost
The robotic welding system delivered impressive results, addressing the customer’s key challenges:
50-60% Productivity Increase
Automation significantly reduced production time, enabling faster throughput.
Better Weld Penetration
The advanced MIG system ensured strong, consistent welds with minimal rework.
Safer Workflow
Automation eliminated manual handling, creating a safer production environment.
Suitable Applications
Versatility in Heavy Fabrication
The heavy-duty robotic welding system is ideal for a wide range of applications, including:
Agricultural Machinery
Perfect for large, complex components requiring multi-plane welds.
Mining Equipment
Handles heavy assemblies with precision and consistency.
Heavy Fabrication
Designed for robust, full-penetration welds on large parts.
Whether you’re producing agricultural machinery or other heavy-duty products, this system offers the precision, safety, and efficiency you need to stay ahead.
Ready to Automate Your Welding Process?
Contact Infinite Robotics today to learn how our robotic solutions can transform your operations and help you achieve your goals.