Automation·Integration·Robotics

Challenge

Cut cycle times and raise consistency in critical laser welding applications across multiple materials and thicknesses, while reducing manufacturing defects.

Solution

Full integration of a robotic cell built around a high-performance Collaborative Robot FR5 coupled to a high-precision IPG Photonics laser welding unit (Everlast Redsabre 3000x). A custom mount was engineered for head stability and an intelligent tool (Joystick) was added so operators can monitor the process in real time.

Result

Thanks to custom-programmed welding paths, the system dramatically increased operational efficiency and precision, achieving a full reduction in assembly defects and rejected parts.

Challenge

Fully eliminate the severe health and safety risks faced by manual welders who had to enter 2.1-meter-diameter silos, exposing themselves to mechanical injuries and highly toxic gases.

Solution

Development and fabrication of an interior robotic welding system assisted by advanced control cabinets. The solution uses a FAIRINO FR20 cobot (1,854 mm reach, 20 kg payload) mounted on a 1-meter pneumatic lifting base, integrating a Miller MIG welder and an industrial laser vision system that guides the start of the weld bead with millimetric precision.

Result

100% mitigation of occupational risks by automating work in confined spaces. Beyond protecting personnel, the system delivered a substantial increase in production speed and uniform, top-quality welds, with rapid payback on operating costs.

Challenge

Flexibly automate the transfer of parts from lateral conveyors into processing nests, eliminating sorting errors and quality issues caused by manual component handling.

Solution

Design and assembly of a workstation that integrates a Fairino FR3/FR5 collaborative arm together with a custom-built lateral transfer conveyor and a specialized gripper that secures each part. Control is structured through CompactLogix PLC digital modules and custom HMI interfaces.

Result

The cobot performs pick-and-place tasks, removing material from the conveyor and positioning it precisely in the nests. Our in-house software gives the station the ability to automatically distinguish left and right parts, or sort by part number — fully user-configurable from the HMI settings screen.