Robot Weld Cells and Automated Welding Systems

At Ergonomic Partners, we understand the challenges manufacturers face in today's competitive landscape. For decades, we've been a leader in material handling solutions, ensuring seamless workflow and optimized production lines. This expertise perfectly translates to the world of welding automation.

We're your one-stop shop for a seamless transition to robotic welding. We offer a complete suite of services, from initial consultation and system design to flawless integration, installation, and operator training. We also collaborate with leading robot and welding equipment manufacturers, including Yaskawa and Fronius, ensuring access to the latest technologies and ongoing support. Explore our solutions below to see how Ergonomic Partners can transform your welding operations.

Benefits of Welding Automation

Welding is a critical process in many industries, but it can also be labor-intensive, time-consuming, and even dangerous. Robotic welding systems offer a powerful solution to these challenges. Welding automation utilizes robots for precise, high-speed welding, boosting productivity and quality. Several robotic welding processes exist, like MIG (versatile), TIG (precision), arc (cost-effective), and laser (deep penetration).

• Production rates: Robots work tirelessly, exceeding manual welding speeds for quicker completion and frees up skilled welders for complex projects.
• Weld quality: Precise robotic movements ensure consistent weld parameters and minimize defects.
• Cost efficiency: Automation reduces reliance on manual labor, lowers rework rates, and improves overall production efficiency.
• Worker safety: Robots shield workers from exposure to welding fumes, sparks, and other hazards.
• Project planning: Consistent cycle times allow for accurate planning and lead times.

Custom Engineered Robot Welding Cells

Our team of robot weld engineers and mechanical design specialists collaborate closely with you to understand your specific needs and develop a tailored welding automation solution. This may include:

• Welding Fixture Design: Creating a secure and efficient holding system for your workpieces.
• Optimal Cell Layout: Designing the physical layout of your robotic welding cell for optimal workflow.
• Delivery Cart/Rack Design: Ensuring efficient part loading and unloading processes.
• Safety System Design: Prioritizing worker safety with proper shielding, fume extraction, and emergency stop features.
• HMI with PLC Logic: Developing a user-friendly interface for part-type selection and overall system control.
• Weld Path Programming: Creating the precise robot movements for accurate and efficient welds.
• Optional Laser Seam Tracking and Vision System Integration: Incorporating advanced technologies for even greater weld precision and flexibility.

Pre-Engineered Automated Welding Systems by Yaskawa

Ergonomic Partners is proud to offer a range of pre-engineered automated welding systems by Yaskawa Motoman. These pre-configured robotic welding cells provide a cost-effective and efficient way to integrate automation into your welding operations.

Yaskawa Welding Robot Options:

Yaskawa's ArcWorld series offers a variety of pre-engineered welding cell configurations to suit diverse applications. These cells typically include:

• Compact Footprint: Sizes ranging from 7 ft x 10 ft to 13 ft x 20 ft provide space-saving solutions for various production environments.
• Robot Options: Choose between configurations with 1, 2, or 3 Yaskawa robots to meet the complexity and throughput demands of your project.
• Work Positioning: Options include work positioners, tables, or Ferris wheel designs for optimal weld access and flexibility.
• Accessories: Ergonomic Partners can integrate additional Yaskawa-approved options like tip change boxes, spool kits, exhaust hoods, safety fencing, stack lights, and HMI operator stations to further enhance your pre-engineered system.

Fronius Robotic Welding

Fronius offers several advanced options that could benefit your weld cell applications. For example, if you have an application that requires higher production, you could upgrade from a gas-cooled system to a liquid-cooled one. Or if you have an application that requires manual welding touch-ups, we provide an option to flip a switch on the welder allowing welders to perform manual torch welds. As an authorized Fronius robotic welding integrator, we can analyze and specify the right welder for your application.

Fronius Welding Process Options:

• PMC (Pulse Multi Control): This innovative technology provides precise control over the arc, significantly reducing heat input and spatter for cleaner welds, especially with thin materials.
• LSC (Low Spatter Control): This process utilizes a modified dip transfer arc for outstanding stability and minimal splatter. LSC allows for high-quality welds while achieving a faster deposition rate, ideal for production environments.
• CMT (Cold Metal Transfer): This unique process utilizes extremely low heat input, making it perfect for joining thin materials like aluminum and steel. CMT even allows for brazing galvanized metal sheets with minimal distortion, expanding the range of applications for your robotic welding system.

Stainless Steel Robot Welding

Aluminum Robot Welding

Carbon Steel Robot Welding

Other Robotic Welding Arm Options

While Ergonomic Partners is a master integrator for Yaskawa and Fronius, we are also distributors for KUKA and Fanuc. Upon request, we work with industrial-grade welders and coordinate with end users who use brands such as Lincoln or Miller systems.

Robot Welding Documents and Information

Ergonomic Partners designs, builds, and manufactures robotic welding cells nationwide, focusing on Missouri, Illinois, Indiana, Kansas, Arkansas, Florida, Georgia, South Carolina, North Carolina, Tennessee, Nebraska, Kentucky, Iowa, and Oklahoma.