{"id":1926,"date":"2021-11-16T18:48:58","date_gmt":"2021-11-16T17:48:58","guid":{"rendered":"https:\/\/www.sistec-am.com\/uncategorized\/hold-weld-automation-a-revolution-in-heavy-and-complex-structural-welding\/"},"modified":"2026-05-08T17:35:33","modified_gmt":"2026-05-08T15:35:33","slug":"hold-weld-automation-a-revolution-in-heavy-and-complex-structural-welding","status":"publish","type":"post","link":"https:\/\/www.sistec-am.com\/en\/case-history\/hold-weld-automation-a-revolution-in-heavy-and-complex-structural-welding\/","title":{"rendered":"“Hold & Weld” automation: a revolution in heavy and complex structural welding."},"content":{"rendered":"

Business challenges<\/strong><\/p>\n

The project presented technical complexities that directly impacted productivity:<\/p>\n

    \n
  1. Extreme variability<\/strong>: the impossibility of creating clamping jigs for numerous small parts due to their variable positioning.<\/li>\n
  2. Critical dimensions<\/strong>: managing workpieces up to 3.5 meters long, requiring extensive reach and operating ranges.<\/li>\n
  3. High downtime<\/strong>: loading and clamping heavy, bulky structures occupied a disproportionate fraction of the total cycle time.<\/li>\n
  4. Loading logistics<\/strong>: the need to use overhead cranes to move structural components within an area densely occupied by robots mounted on slides.<\/li>\n<\/ol>\n

    \"collage<\/p>\n

    Strategic solution<\/strong><\/p>\n

    The system architecture was engineered to maximize masked time and operational flexibility:<\/p>\n

      \n
    • Triple-robot configuration on slides<\/strong>: two KUKA IONTEC robots dedicated to welding and a third high-precision (HA) KUKA robot for real-time handling and positioning.<\/li>\n
    • “Robot-as-jig” technology<\/strong>: the handling robot positions small components with millimeter precision while the welding robot performs tack-welding, eliminating the cost and clutter of hundreds of fixed jigs.<\/li>\n
    • Dual mobile “lathe” stations<\/strong>: two welding fixtures mounted on separate sliding carriages. This system brings the loading zone outside the robots’ footprint, allowing for easy and safe use of overhead cranes.<\/li>\n
    • Self-adaptive welding fixtures<\/strong>: the handling robot automatically adjusts the fixture length by moving mobile sections along ball-recirculation guides, adapting instantaneously to the specific model being welded.<\/li>\n
    • Automatic tool changer<\/strong>: management of various gripping systems via a dedicated magazine and electro-pneumatic automatic changers mounted on the robot’s wrist.<\/li>\n<\/ul>\n

      \"robotic<\/p>\n

      Results and generated value<\/strong><\/p>\n

      The integration of these technologies enabled the achievement of superior business objectives:<\/p>\n

        \n
      • Cycle time reduction<\/strong>: achieved through simultaneous welding by two robots on the same workpiece (made possible by the length of the structure).<\/li>\n
      • “Masked time” efficiency<\/strong>: while one side of the system is welding, the operator loads structural parts onto the second external carriage, eliminating machine downtime.<\/li>\n
      • Total model flexibility: the system automatically reconfigures for variable lengths ranging from 2,000 to 3,500 mm without any manual intervention on the equipment.<\/li>\n
      • Space optimization<\/strong>: the use of sliding carriages for the fixtures resolved the conflict between the robots’ footprint and the maneuvering space required for heavy loads.<\/li>\n<\/ul>\n

        Technical specifications and equipment<\/strong><\/p>\n

          \n
        • Welding systems<\/strong>: 2x KUKA KR20 R3100 IONTEC mounted on linear slides to ensure maximum operational coverage.<\/li>\n
        • Handling unit<\/strong>: 1x KUKA KR120 R3100-2 HA (High Accuracy) on a slide, optimized for millimeter-precise component positioning.<\/li>\n
        • Dimensional capacity<\/strong>: designed to handle structures with cross-sections up to 1000×600 mm and extended lengths up to 3500 mm.<\/li>\n
        • Process Integration<\/strong>: welding power sources and peripherals integrated directly onto the slide\u2014a strategic design choice that guarantees maximum freedom of movement and eliminates interference during complex machining tasks.\"two<\/li>\n<\/ul>\n","protected":false},"excerpt":{"rendered":"

          Business challenges The project presented technical complexities that directly impacted productivity: Extreme variability: the impossibility of creating clamping jigs for numerous small parts due to their variable positioning. Critical dimensions: managing workpieces up to 3.5 meters long, requiring extensive reach and operating ranges. High downtime: loading and clamping heavy, bulky structures occupied a disproportionate fraction…<\/p>\n","protected":false},"author":1,"featured_media":1925,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[5],"tags":[],"class_list":["post-1926","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-case-history"],"acf":[],"yoast_head":"\n"Hold & Weld" automation: a revolution in heavy and complex structural welding. | Sistec<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.sistec-am.com\/en\/case-history\/hold-weld-automation-a-revolution-in-heavy-and-complex-structural-welding\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\""Hold & Weld" automation: a revolution in heavy and complex structural welding. | Sistec\" \/>\n<meta property=\"og:description\" content=\"Business challenges The project presented technical complexities that directly impacted productivity: Extreme variability: the impossibility of creating clamping jigs for numerous small parts due to their variable positioning. 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