Overview
A Regional Manufacturer’s Welding Challenge
A manufacturer in regional NSW, known for ute fit-outs such as toolboxes, trays, and accessories, struggled to achieve clean, consistent welds on thin aluminium sheets while also needing to boost production. Because their products require neat welds and large assemblies need long, continuous welds, the company needed a solution that offered precision, speed, and repeatability.
The Challenges
The Roadblocks to Efficiency
The manufacturer encountered several obstacles that hindered their operations:
Cycle Times
Manual TIG welding was too slow to keep up with production demands.
Material Sensitivity
Thin aluminium sheets were prone to burn-through, making precision welding a necessity.
Appearance-Critical Welds
The final product required clean, cosmetic welds that were consistent across batches.
Large Assemblies
Welding large parts required long, continuous welds, which were difficult to achieve manually without compromising quality.
To solve these problems, the company needed a robust automated solution to streamline its work and achieve better results.
The Solution
Control and Speed
Infinite Robotics provided an Australian-made Dual-Station Industrial Robot Welding System to solve these issues. This system was built to handle the unique demands of welding thin aluminium components with precision and control.
Key features of the solution included:
FANUC ArcMate 120iD/12L Robot
Integrated with a Fronius CMT (Cold Metal Transfer) system, offering advanced capabilities for welding thin aluminium with minimal heat input.
Dual Workstations
Operators could load parts on one side while the robot welded on the other, maximising productivity.
1000kg Payload Positioners
Each station was equipped with positioners that synchronised welding and rotation, ensuring complete access to all welds in the optimal position.
Large Part Capability
The system could handle parts up to 3,000mm long, 1,500mm wide, and weighing up to 1,000kg.
Low-Heat Input Process
This minimised distortion, ensuring clean, cosmetic welds even on thin materials.
This ready-to-use solution was made to meet the customer’s current needs and help prepare their business for the future.
Key Features & Capabilities
Precision Meets Productivity
The industrial robot welding system gave the manufacturer many benefits:
Clean, Cosmetic Aluminium Welds
The Fronius CMT system ensured a flawless finish, critical for appearance-sensitive products.
High Repeatability
Consistent quality across all product sizes and batches.
Reduced Distortion
The low-heat input process minimised warping, even on thin materials.
Large Part Handling
The system’s capacity to weld large assemblies made it ideal for ute trays and toolboxes.
Implementation
A Seamless Transition to Automation
Infinite Robotics supplied the system as a ready-to-use solution, ensuring a smooth, easy setup. The process included:
Installation and Commissioning
The system was installed and fully operational in a short timeframe, minimising downtime.
Operator Training
Comprehensive training ensured that the customer’s team could quickly adapt to the new system and start production immediately.
The simple design and easy-to-use programming enabled operators to achieve good results right from the start.
The Results
Reduced Time and Greater Consistency
After installing the dual-station industrial robot welding system, the results were impressive:
Significant Reduction in Cycle Times
The automated system drastically outperformed manual TIG welding, boosting productivity.
Huge Reduction in Rework and Grinding
Clean, precise welds reduced the need for post-weld finishing, saving time and resources.
Consistent Cosmetic Finish
The system delivered flawless welds across batches, meeting the customer’s high standards for appearance-critical products.
These changes solved the manufacturer’s main problems and set them up for long-term success in a tough market.
Suitable Applications
Versatility in Action
The industrial robot welding system is ideal for a wide range of applications, 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 ute fit-outs or other aluminium products, this system offers the precision and efficiency you need to stay ahead.
Ready to Improve Your Welding Capabilities?
Contact Infinite Robotics today to find out how our robotic solutions can transform your operations and help you reach your goals.