Robotic solution · Gist Point
Robotic structural steel welding
Weld beams, columns and chassis without programming the robot part by part.
Ideal for: Steel structures, trailers, towers and non-standard parts in small batches.
- No point-by-point programming
- Tolerates imperfect fit-up
- Small batches and one-off parts
- Plate thickness
- 6–30 mm
- Fit-up error tolerated
- ±30 mm
- Angle deviation corrected
- 8°
- Axes depending on the part
- 6–9
What it includes
What a cell comes with
Laser seam finder
Scans the part, finds each joint where it really is and measures where it starts and ends.
3D-model software
Builds paths and torch positions from the part's model, and simulates them before welding.
Arc tracking
Corrects the path in height and sideways while welding, with weaving.
6 to 9-axis robot
Fixed, on a rail, hanging or on a gantry, with or without a positioner depending on the part size.
What it is for
What gets automated
In steel structures almost no part repeats and fit-up is never perfect, so teaching the robot point by point does not pay off. This system starts from the part's 3D model, scans it with a laser to find each joint where it really is, and corrects the path while welding with arc tracking. It mounts on a fixed 6-axis robot, on a rail or on a gantry, with or without a positioner.
- H-beams, stiffeners, gussets and brackets
- Box columns with multi-pass bevel welds
- Trailer and agricultural machinery chassis
- Towers, bridges, transformer tanks and bases
Typical parts
What parts it welds
Before you ask
Does your part qualify?
If your part meets these points, it is a candidate. Send us the drawing or a photo and we confirm it with a simulation.
- 01Carbon or low-alloy steel, 6 to 30 mm thick.
- 02Fit-up and position within ±30 mm, with up to 8° of angle deviation.
- 03Fillet gap up to 3 mm (leg of 8 mm or more) or 2 mm (leg of 5 to 8 mm).
- 04Bevels within ±1 mm, 0 to 5° angle and up to 25 mm deep; butt joints with a 3 to 5 mm gap.
- 05Welds of 30 mm or more and parts at least 10 mm tall to locate them.
- 06Joint reachable from above or from the side for the laser and the torch.
Clear expectations
What it can and cannot do
It can
- Weld different parts without teaching the robot every point.
- Find the joint even if the part is off by up to 30 mm.
- Fill bevels in several passes and fill the crater when the arc stops.
- Follow corners, go around through-holes and weld several seams in a row.
It cannot (without help)
- Weld galvanized or aluminum parts: reflections prevent reading the joint.
- Reach hidden joints where the laser or torch cannot get in.
- Make up for fit-up out of tolerance or gaps wider than the weave.
What it takes
Robots and models for this application
FAQ
Frequently asked questions
Does each part have to be programmed?
Not point by point. The system takes the part's 3D model, scans it with a laser to locate each joint and generates the path and torch position. A technician reviews the simulation before welding.
How accurate does the fit-up have to be?
Up to 30 mm of error between fit-up and position, 8° of angle deviation and 30 mm of difference in weld length. The gap must be within what weaving covers: up to 3 mm on large fillets.
What part size can it weld?
With a fixed 2 m reach robot, an area of up to about 1,200 × 2,000 mm. On a rail, the rail sets the length. With the robot hanging from an overhead rail, up to 2,200 mm wide (2 m robot) or 1,300 mm (1.4 m robot). On 8 and 9-axis gantries, the axis travel sets it.
What weld quality does it achieve?
ISO 5817 quality level C (or GB 50661 grade III) for fillets and partial-penetration bevels. Full penetration is assessed case by case.
Which materials can it not weld?
Galvanized and aluminum parts, because reflections prevent reading the joint (aluminum also has no arc tracking). Mirror-polished surfaces also hinder vision. Stainless steel is assessed with tests.
Which gases and wires does it use?
MIG/MAG welding with 80% argon and 20% CO₂, 100% CO₂ or 95% argon and 5% O₂, and 1.0, 1.2 or 1.6 mm solid wire or 1.2 mm flux-cored wire. It welds flat, horizontal fillet, horizontal and vertical up or down.
Guides
Guides on robotic structural steel welding
Other solutions
View all solutions
Next step · Gist Point
Want to automate this process?
Send us photos or a video of the part and the process, and we will tell you whether and how to automate it.