Overview
Meeting Diverse Welding Needs
A major agricultural parts manufacturer in regional Queensland faced unique challenges in welding both small, high-mix components and large, heavy-duty parts. The company needed a flexible solution to handle small assemblies efficiently while also automating the welding of larger components requiring rotation. With a skilled labour shortage and a need to increase throughput, the manufacturer sought a comprehensive robotic welding solution.
The Challenges
Diverse Needs, One Solution
The manufacturer encountered several obstacles that impacted their operations:
Small Parts
High-mix, low-volume components required a flexible and repeatable solution.
Large Parts
Heavy components needed frequent manual repositioning, slowing production.
Skilled Labour Shortage
The regional location made it difficult to find and retain skilled welders.
Throughput and Cost Pressures
The company needed to increase production speed while reducing costs.
To address these challenges, the manufacturer required a dual robotic solution capable of handling both small and large components with precision and efficiency.
The Solution
A Mixed Robotic Welding System
Infinite Robotics delivered a tailored solution that combined collaborative and industrial robotic systems to meet the customer’s diverse needs. The solution included:
FlexWeld Single Station Cobot Welding System:
- Equipped with a FANUC CRX10iA/L collaborative robot.
- Integrated with a Kemppi A7 Pulse MIG system, offering stainless steel welding capabilities.
- Designed for high-mix, low-volume small components.
Single Station Industrial Robot Welding System:
- Featuring a FANUC ArcMate120iD/12L industrial robot.
- Integrated with a Kemppi A7 MIG system and a 1000kg payload welding positioner.
- Built for large, heavy-duty components requiring rotation.
Key Features & Capabilities
Flexibility Meets Precision
The mixed robotic welding system offered numerous benefits, including:
High Flexibility for Small Batches
The cobot system adapted to high-mix, low-volume production with ease.
Robotic Rotation for Large Components
The industrial robot system ensured precise, distortion-free welds on heavy parts.
Weld Consistency Across Categories
Both systems delivered uniform, high-quality welds, reducing rework.
Scalable Cell Layout
The modular design allowed for future expansion as production needs grew.
Implementation
A Seamless 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
Both systems were installed and fully operational in a short timeframe.
Comprehensive Training
Operators received hands-on training to quickly adapt to the new systems and maximise their capabilities.
The intuitive design and user-friendly programming allowed the customer’s team to achieve excellent results from day one.
The Results
Factory-Wide Improvements
The mixed robotic welding system delivered impressive results, addressing the customer’s key challenges:
Reduced Bottlenecks
Streamlined production across both small and large product lines.
Improved Quality
Consistent welds reduced rework and improved overall product quality.
Faster Turnaround
Increased throughput across the entire factory.
Upskilled Workforce
Current welders were trained to operate the robotic systems, enhancing their skillsets.
These improvements not only solved the customer’s immediate challenges but also positioned them for long-term success in a competitive market.
Suitable Applications
Versatility in Mixed Production
The mixed robotic welding system is ideal for a wide range of applications, including:
Agricultural Components
Perfect for both small, high-mix parts and large, heavy-duty assemblies.
Mixed Production Environments
Handles diverse product categories with ease.
High-Mix Fabricators
Designed for manufacturers with varying production needs.
Whether you’re producing agricultural components or other mixed products, this system offers the flexibility, precision, 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.