Automated Welding Cell

The client needed to reduce manual TIG welding cycle time on aluminum chassis components by 60%, while maintaining ±0.3mm repeatability across 3-shift production.

Designed and integrated a 2-robot synchronized welding cell with vision-guided seam tracking, custom fixturing, and a Siemens S7-1500 safety PLC.

We began with a full DFA (Design for Automation) audit of the part geometry. A KUKA KR 16 arc was paired with a positioner to achieve full 6-axis torch access. Vision calibration was performed with a Cognex In-Sight system, and we wrote custom Structured Text routines for adaptive torch speed.