Overview
Tackling Large-Scale Welding Challenges
A regional NSW manufacturer specialising in steel chassis and frames faced significant challenges in welding large, heavy components. With parts up to 8 metres long and 2 metres wide, the company needed a solution to improve efficiency, quality, and safety while reducing production time.
The Challenges
Overcoming Size and Complexity
The manufacturer encountered several obstacles that hindered their operations:
Oversized Components
Standard robots couldn’t reach the full length of the large chassis and frames.
Quality Issues
Maintaining consistent quality on long, continuous, high-amperage welds was difficult.
Time-Intensive Process
Manual welding took nearly two days per chassis, slowing down production.
Safety Concerns
Handling and rotating large, heavy frames manually posed significant safety risks.
To address these challenges, the company required a robust automated solution capable of handling large-scale components with precision and efficiency.
The Solution
Precision Welding for Large Frames
Infinite Robotics delivered a custom Australian-made robotic welding system tailored to the customer’s needs. The solution included:
Track-Mounted FANUC ArcMate M710iC/12L Robot
A long-reach industrial robot capable of traversing the full length of the frame for complete coverage.
2,000kg Payload Welding Positioner
A heavy-duty headstock that rotated the workpiece, ensuring optimal welding positions for consistent results.
Fronius TPS/i 500A Water-Cooled Pulse MIG Welding System
Provided precise, high-amperage welds with minimal distortion.
Key Features & Capabilities
Efficiency Meets Safety
The robotic welding system offered numerous benefits, including:
Full Coverage of Large Components
The track-mounted robot and positioner ensured complete access to oversized parts.
Reduced Distortion
Controlled rotation and weld sequencing minimised warping, even on long seams.
Heavy-Duty Fixturing
Safely managed the rotation and handling of large, heavy frames.
Consistent Weld Quality
Delivered repeatable, high-quality welds across all products.
Improved Safety
Automation eliminated the need for manual handling, reducing workplace risks.
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
Faster, Safer, and More Consistent
The robotic welding system delivered impressive results, addressing the customer’s key challenges:
60-70% Reduction in Cycle Time
Automation drastically reduced production time, enabling faster throughput.
Highly Consistent Welds
The advanced MIG welding system ensured repeatable, high-quality results.
Improved Safety
Automation eliminated manual handling, creating a safer production 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 Heavy Fabrication
The heavy-duty robotic welding system is ideal for a wide range of applications, including:
Chassis Fabrication
Perfect for large, complex steel frames.
Trailers
Handles long, heavy components with precision.
Structural Frames
Ensures consistent, high-quality welds for structural integrity.
Heavy Fabrication
Designed for robust, full-penetration welds on large parts.
Whether you’re producing chassis, trailers, 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.