Welding robot systems and automatic welding machines

If you have a large number of identical or similar welding assemblies or components with very long weld seams, or if you do not have the appropriately qualified welders available, then welding robots will solve your problems.

As a system house of "Fanuc" we own:

  • 35 years of experience with all welding processes
  • 30 years of experience in welding fixture construction
  • experience with welding robots for 20 years.

 

This means that we are one of the few system houses in a position to plan, design and manufacture your very special robot welding system completely in-house and to support it until it is ready for production. This means that you receive an "all-round carefree package" from us.

We offer you a cost-effective sample welding with a welding-technological consideration of the entire task. 

We are also well-equipped to ensure the optimum welding process for your welding task, the appropriate welding equipment manufacturer and optimised welding parameterisation. The use of our own developments and property rights can also be very valuable in the implementation of your robot welding system.

By combining several welding robots, handling robots, grinding robots, rotary and traversing axes, as well as special seam tracking systems, we are able to respond to all your challenges.

Förster robot welding systems

The starting point for our robot welding system construction is the situation that we can offer standard robot cells quite cheaply, but the customer components are usually not suitable for a standard cell. 

Accordingly, it is our strength to specifically address customer-specific requirements when building a robot welding system.

We unite:

  • Welding technology
  • Process engineering
  • Fixture construction
  • Robotics
  • Control and programming
  • Training and support

Welding technology

Together with our Welding engineers and welding specialists, we develop efficient solution proposals as a quotation concept based on the respective customer and component-specific requirements. As a result, sample welds can be carried out on customer components on an available robot system in order to be able to anticipate the expected results.

Process engineering

According to the respective welding task, we select the required welding process and the most suitable welding equipment manufacturer. As an independent system house, we have access to every manufacturer. In cooperation with colleges and universities, we also find new innovative solutions for your projects, if required.

Fixture construction

Our 30 years of experience in the Welding fixture construction form the basis for our designers and specialists to provide the actual heart of a customer-specific robot system, the welding fixture, in high quality.

In addition to the exact positioning and clamping of the individual parts, the all-round accessibility to the welding seams, the protection against welding spatter and the counteracting of the resulting welding distortion should be taken into account.

Experience has shown that it is much more advantageous to use a high-quality device to ensure the exact position of the components than to have to correct deviations with seam tracking systems.

However, if seam tracking becomes necessary, this can be done by

  • by 3D scanning of the seam beginning and end
  • by stress monitored oscillation in the V- and fillet welds
  • by laser scanner
  • by camera

take place.

Robotics

The "Förster" system house primarily uses welding robots from the market leader "Fanuc", which are characterised by an easy-to-operate and absolutely stable control system.

The welding power source is simply connected to the robot via fieldbus interfaces such as Ethernet CAT.

The Fanuc robot has high path accuracy and high reaction speeds to ensure maximum productivity.

Primarily 6-axis robots with a powerful control unit are used, via which other robots or additional axes can be synchronously controlled and the necessary safety circuits can also be integrated.

The great variety of Fanuc robots enable us to select the optimum robot for every application.

Control and programming

For each robot system, our engineers create an overall control concept for the integration of the robots to be linked (handling and welding robots), further additional axes, the welding devices, additional options (torch correction and cleaning devices), seam tracking systems, welding smoke detection, safety technology and additional control technology.

From this, circuit diagrams and the control cabinet construction are derived and realised accordingly.

After the robot welding system has been manufactured, the robot and its movement axes are programmed according to the component coordinates and the positions to be welded. In continuation of the programming, it is now necessary to teach the robot all the arts of an ingenious welder and to parameterise and save the individual welding programmes. .

Now the robot welding system is ready to go!

Training and support

When the system is commissioned at Förster prior to delivery, the first sample welding of the customer's component takes place. As a rule, the component is programmed ready for welding together with the customer's future system operator.

This familiarisation with the individual steps is mastered in 3 to 5 days, depending on the task.

All further questions arising in later practical use can normally be solved cost-effectively in telephone support. In addition, we are always available for further practical support and service.

Even with these fixtures you will find elements from our modular system.

Experimental set-up from the Fraunhofer Institut Chemnitz
Welding Robot Automation-Förster-Welding-Systems
Welding Robot Automation-Förster-Welding-Systems
Welding Robot-Single-System-Förster-Welding-Systems
Welding Robot-Single-System-Förster-Welding-Systems

The most important data at a glance:

  • For assemblies up to 6t and max. dimensions of 6 x 3 x 3m
  • Fanuc robot with 9 robot axes (12 motion axes)
  • With 2 separately controllable positionersSingle and tandem operation possible
  • MAG robot power source Lincoln PowerWave
  • Completely pre-assembled enclosure with safety monitoring

Standard solutions with robot

For simple and changing welding tasks, you can also choose from a range of low-cost standard welding cells, which can of course also be extended and adapted.

Welding robot with jig table

Welding robot with 2-station table

  • Table surface 2400×1200
  • Slot system made of grey cast iron
  • Option aluminium-copper
  • Robot Arc Mate 0iB Fanuc
  • Power source MIG 300A pulse
  • Optional torch cleaning station
  • Optional fume extraction
  • Optional enclosure

Welding robot with 2-station shutle table

  • Table surface 2400×1200
  • Slot system made of grey cast iron
  • Option aluminium-copper
  • Robot Arc Mate 0iB Fanuc
  • Power source MIG 300A pulse
  • Optional torch cleaning station
  • Optional fume extraction
  • Optional enclosure

Welding robot with positioner

  • Frame device made of X-Pro profiles with slot system
  • Robot Arc Mate 0iB Fanuc
  • with Positioner up to 1000 Kg
  • Power source MIG 300A pulse
  • Optional torch cleaning station
  • Optional fume extraction
  • Optional enclosure

Welding robot with rotary axis and counter bearing

  • Centre distance 2 metres
  • Positioner up to 1000 kg
  • Robot Arc Mate 0iB Fanuc
  • Power source MIG 300A pulse
  • Optional mouvable counter bearing
  • Optional fixture frame
  • Optional torch cleaning station
  • Optional fume extraction
  • Optional enclosure

Welding robot with 2-axis positioner

  • Robot Arc Mate 0iB Fanuc
  • Robot controlled 2-axis positioner
  • Power source MIG 300A pulse
  • Optional torch cleaning station
  • Optional fume extraction
  • Optional enclosure
  • Optional Table top with T-slot system

Welding robot with L-positioner

  • Robot controlled 2-axis positioner
  • Robot Arc Mate 0iB Fanuc
  • Power source MIG 300A pulse
  • Optional torch cleaning station
  • Optional racuh extraction
  • Optional enclosure
  • Optional table top with T-slot system

Welding robot with H-turner

  • Motorised rotating 2-station changing system
  • 2 times positioner with counter bearing
  • Robot Arc Mate 0iB Fanuc
  • Power source MIG 300A pulse
  • Optional torch cleaning station
  • Optional fume extraction
  • Optional enclosure

Call us or use our contact form to find a trustworthy answer to the question "robot useful or not". We can also provide you with a sample weld or a process study on your component at a reasonable price as a basis for your decision.

Welding robots for industry and trade - More speed and quality

Welding robot-with-T-slot-welding-table-Förster-Welding-Systems
Welding robot with T-slot welding table
Welding robot-automation-details-yellow-Förster-Welding-Systems

"It's much easier, to teach a welder to program than to teach a programmer to weld!"

Due to the increasing shortage of skilled workers, companies are increasingly forced to automate welding processes. Robots offer ideal conditions for this compared to conventional welding by hand.

In the meantime, robotic welding is already becoming interesting for small companies, as the acquisition costs for robots ready for welding already start at less than 60,000 €.Compared to manual welding, welding robots achieve a much higher and more reproducible quality of the welds through an optimised welding process with constant parameters. The recording and monitoring of the process parameters during robotic welding allow easy evaluation for quality assurance. Rework can often be avoided due to the uniformity of the seams and the reduced amount of weld spatter. The use of robot-controlled additional axes is possible for very fast positioning in an always ideal welding position, thus minimising costs arising from non-productive time.

In addition, welding robots help to protect the health of employees - on the one hand, the amount of harmful welding fumes and toxic metal vapour inhaled is minimised, and on the other hand, the physical strain caused by handling heavy components and the psychological strain caused by monotonous welding tasks can be reduced.Continuously developed, innovative operating and control systems are increasingly helping to make robot welding systems intuitive and easy to operate. The high readiness for use and reliability distinguish the robot in the welding sector.

In industrial and series production, the use of welding robots is a common practice. For the production of small series, we offer a complete welding robot solution with plasma cutting and stud welding equipment as well as plasma cutting technology as one unit. When robot welding on different components, an optimum of interaction is necessary: starting with the process-related possibilities of the seam design, through the component-specific positioning of the assembly individual parts, up to the programming of the welding robot in interaction with further movement axes. Thanks to our many years of experience in the field of welding robots and automation, we can provide complete solutions for the requirements set.

Technological considerations for robot welding

Already in the planning phase, the technological consideration based on the expected quantities and quality requirements should be the basis for further decisions in robot welding.

This should include the following considerations:

  • special possibilities of modern welding processes
  • the positioning and clamping of the individual components to form the complete assembly
  • the accessibility of the welding robot to the individual welding seams in an optimal welding position
  • the handling of component feeding and removal
  • the constant positioning of the component during welding
  • the single-axis or multi-axis movement of the robot during welding
  • the expected welding and intermediate times
  • the welding distortion to be expected and limited
  • the weld seam sequence
  • the component position detection
  • the automatic seam tracking
  • the aspect of occupational health and safety

Welding robot and positioner working together

The Coordinated Motion function allows a robot to follow the movements of a workpiece positioner. The movement of the robot follows the relative movement of the workpiece on the positioner.

Welding robot Coordinated Motion Variant 2 Förster Welding Systems

Automatic welding machines for mechanised series production

Automatic welding machine for the serial production of anchor channels

  • the base rail is drawn in the programme controlled in the desired stages
  • at the welding point of the anchors, the base rail is automatically pre-tensioned during the welding process
  • the anchors to be welded on are taken from the magazine, pressed onto the base rail and welded on both sides
  • the welding process is evaluated and stored

We manufacture customised solutions especially for your requirements.

Welding Robot-Mechanically Automated Circumferential Welding Förster Weldig Systems

Mechanically automated circumferential welding

Circular seam welding is frequently used in tank construction. We manufacture customised welding systems for the mechanised welding of circumferential seams.

  • of various materials
  • with the Mig/Mag, Tig, and plasma welding processes
  • with component-specific positioning and clamping devices
  • with mechanical, pneumatic and vacuum clamping
  • with controlled tracks and position scans

Mechanical longitudinal and corner seam welding

Longitudinal seam welding and corner seam welding frequently occur in enclosure construction. We manufacture customised welding systems for the mechanised welding of longitudinal and corner seams.

  • of various materials
  • with the Mig/Mag, Tig, and plasma welding processes
  • with component-specific positioning and clamping devices
  • with mechanical, pneumatic and vacuum clamping
  • with controlled tracks and position scans
Welding Robot-Mechanical-Automated-Corner-Seam-Welding-Förster-Weldig-Systems
Welding robot-Mechanically automated corner seam welding-Förster Welding Systems

Do you have any questions?

03723 40180

We will be happy to advise you individually and comprehensively. Call us or use our contact form.

One of our qualified employees will be happy to take the time to address your individual requirements!

FÖRSTER welding systems GmbH
Gewerbering 21-23
09337 Hohenstein-Ernstthal

Phone: +49 (0) 3723 4018 0
Fax: +49 (0) 3723 4018 18
E-mail: info@weldingsystems.de

Phone-200x60