Station Workflow

• Station 1 (Assembly & Tack Welding): Designed for assembling and circumferential tack welding of two component halves. Custom positioning fixtures with centering pins ensure precise alignment and angular orientation of the parts.
• Station 2 (Automated Double-Sided Welding): An integrated pneumatic manipulator automatically picks workpieces from the inlet chute, which holds 5–8 pieces, and clamps them into the main fixture equipped with brass mandrels and cooling fins. Welding is performed simultaneously using three robotic torches: one for the main circumferential seam and two angled torches for welding hubs or internal structural elements.
• Automation & Control: The cell is driven by 9 motorized servo axes with cross-slides for precise torch positioning. It is operated via a 10-inch color touchscreen HMI, which supports welding program storage and selection as well as real-time sensor monitoring.

Technical Specifications

• Welding Process: MIG/MAG (optional laser cleaning available)
• Welding Power Sources: 4 Fronius welding power sources with customized machine/robotic torches
• Material Thickness: 1–6 mm
• Workpiece Diameter Range: Min. Ø172 mm – max. Ø404 mm
• Number of Motorized Axes: 9 electric axes
• Motorized Axis Travel (X/Z):
  • X1, X2 and X3 axes: 200 mm
  • Z1 axis: 200 mm
  • Z2 axis: 300 mm
  • Z3 axis: 200 mm
• Clamping Tables & Drives:
  • Station 1 (C-axis): Ø500 mm clamping plate, rotation speed 0.2–4 rpm, torque 8.5 Nm
  • Station 2 (A1/A2 axes): Rotation speed 0.2–4 rpm, torque 8 Nm
• Clamping System: Brass mandrels with cooling fins and a pneumatic spring mechanism with a 20 mm stroke for compensating dimensional tolerances
• Handling System: Pneumatic manipulator with inlet and outlet gravity chutes (storage capacity: 5–8 workpieces)
• Control & Interface: 10-inch color touchscreen HMI with program memory
• Connected Load: 13 kW
• Supply Voltage: 230 V AC / 50 Hz (control voltage: 24 V DC)
• Pneumatic Supply: 4–6 bar (1/2-inch quick connector)
• Overall Dimensions (L × W × H): 3200 × 3500 × 2900 mm
• Total Weight: 3200 kg