Overview
Meeting the Challenges of Large-Scale Welding
A Queensland-based manufacturer of grain silos faced significant challenges in welding large frames and structural subcomponents. With growing demand, skilled labour shortages, and the need for consistent, high-quality welds, the company required an advanced robotic welding solution to improve efficiency and safety.
The Challenges
Overcoming Size and Demand
The manufacturer encountered several obstacles that impacted their operations:
Large, Heavy Components
Repositioning large frames manually was slow and posed safety risks.
High Consistency Requirements
A large number of welds demanded uniform quality across all components.
Slow Manual Welding
Manual processes couldn’t keep up with the growing production demand.
Skilled Labour Shortages
Limited availability of experienced welders made automation essential.
To address these challenges, the company needed a robust robotic welding system capable of handling large-scale components with precision and efficiency.
The Solution
Dual-Station Robotic Welding System
Infinite Robotics delivered an Australian-made dual-station industrial robot welding system tailored to the customer’s needs. The solution included:
FANUC ArcMate 120iD/12L Robot
A long-reach industrial robot designed for high-speed, consistent welding along long seams.
Kemppi AX Pulse MIG System
Provided advanced welding capabilities for large assemblies.
1000kg Payload Positioners
Each station was equipped with positioners that synchronised welding and rotation, ensuring complete access to all welds.
Kemper Variohood Fume Extraction System
A movable fume hood allowed for safe part loading/unloading with an overhead crane while maintaining a clean work environment.
Key Features & Capabilities
Efficiency Meets Safety
The robotic welding system offered numerous benefits, including:
Excellent Reach for Large Assemblies
The robot’s design ensured complete access to oversized components.
High-Speed, Consistent Welding
Delivered uniform weld quality along long seams, reducing rework.
Offline Programming Capability
Simplified setup and reduced downtime by programming directly from CAD models.
Improved Worker Safety
The integrated fume extraction system created a safer work environment.
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 Safety Boost
The robotic welding system delivered impressive results, addressing the customer’s key challenges:
50% Reduction in Cycle Time
Automation significantly increased production speed, enabling faster throughput.
Consistent Weld Quality
Delivered reliable, high-quality welds across all components.
Reduced Manual Handling Risks
Automation eliminated the need for manual repositioning, improving safety.
Improved Worker Safety
The integrated fume extraction system ensured a clean and safe work environment.
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 Action
The dual-station robotic welding system is ideal for a wide range of applications, including:
Agricultural Machinery
Perfect for large, complex components requiring consistent welds.
Mining Equipment
Handles heavy assemblies with precision and efficiency.
Heavy Fabrication
Designed for robust, full-penetration welds on large parts.
Chassis and Trailers
Ensures high-quality welds for structural integrity.
Structural Frames and Defence
Delivers reliable results for critical applications.
Whether you’re producing grain silos or other large-scale components, 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.