Case study

Welding Automation for Suspension Components

Name
Robotic Welding Station
Industry
Automotive
Scope
Design and implementation of a fully robotic welding station for precise welding of components with complex geometries – welding automation for the automotive industry.

Challenge

An automotive client manufacturing suspension systems, mainly shock absorbers, required a solution enabling fast and repeatable welding of parts with intricate shapes.

The project aimed to increase production efficiency, improve weld quality, and minimize the impact of heat input and material deformation.

Technologies and Solutions

2 welding robots integrated with a 5-axis ABB positioner FRONIUS CMT (Cold Metal Transfer) welding technology Control system: Siemens SIMATIC with operator panel Modular design based on a supporting frame and mobile power supply modules Safety systems: ASSA-ABLOY protective gate, SICK safety curtains

Process and Execution

The project started with a detailed analysis of the client’s production requirements, including part geometry, types of welds, and expected efficiency. Based on this data, the team designed a modular solution that can be easily adapted to future production changes. Special attention was given to operator ergonomics and the ability to quickly reconfigure the station.

Results

Flexible adaptation of the workstation to new components

Minimization of deformations and heat impact on the material

Precise arc control and process stability

Joining of components made from different materials

Significant reduction of spatter

Increased efficiency and material savings

High-quality and repeatable welds

Reduced changeover time and improved work safety