Welding Station

The 3D Welding Station is an intelligent processing system designed specifically for welding complex structural components. By integrating multi axis robots, high-precision positioning fixtures, and intelligent control systems, it achieves all-round and multi angle welding of workpieces. Compared with traditional two-dimensional welding, its significant advantage lies in its ability to handle complex parts with spatial surfaces and multi angle welds, which are widely used in high-end manufacturing fields such as automotive manufacturing, aerospace, shipbuilding, and engineering machinery.

Core components and technical architecture

Robot welding system

Six axis or seven axis robots: using industrial grade robotic arms (such as KUKA, ABB, Fanuc, etc.), with a repeat positioning accuracy of ± 0.05mm, can flexibly adjust the welding gun posture in three-dimensional space, and achieve complex trajectory welding.

Welding power supply: Equipped with MIG/MAG, TIG or laser welding power supply according to process requirements, supporting advanced welding modes such as pulse and double pulse, ensuring high-quality connection of different materials (steel, aluminum, stainless steel).

3D positioning and fixture system

Modular fixture platform: A three-dimensional flexible welding platform based on hole or groove systems, which achieves precise fixation of workpieces through fast positioning pins and clamping mechanisms, and is compatible with parts of various sizes and specifications.

Dynamic coordinate system compensation: Real time detection of workpiece position deviation using laser sensors or vision systems, automatic adjustment of welding paths, and elimination of clamping errors.

intelligence control system

Offline programming software such as RobotStudio, WorkVisual, etc. can directly generate welding paths through CAD models, reducing on-site debugging time.

Weld seam tracking technology: Integrated laser vision or arc sensing system, real-time recognition of weld seam position and shape changes, automatic correction of welding parameters, and adaptation to workpiece thermal deformation.

Security protection and human-machine cooperation

Laser protective fence: using safety light curtains or fences to prevent personnel from entering the work area by mistake.

Force feedback collision detection: When the robot comes into contact with an obstacle, it automatically stops moving to protect the safety of the equipment and operators.

Workflow and advantages

Typical workflow

Workpiece modeling: Import the workpiece model through 3D scanning or CAD drawings.

Path planning: The software automatically generates welding trajectories and optimizes the welding sequence to reduce deformation.

Automatic clamping: Robots or humans fix the workpiece on a 3D fixture, and the system automatically recognizes the position of the workpiece.

Intelligent welding: The robot executes welding according to the preset path and adjusts parameters in real time to ensure the quality of the weld seam.

Quality inspection: After welding, defects in the weld seam are detected through visual system or ultrasonic testing.

Core advantages

Accuracy improvement: The three-dimensional spatial positioning accuracy reaches ± 0.1mm, meeting the high-precision requirements of aerospace and other fields.

Efficiency Doubling: Compared to manual welding, the efficiency is increased by 3-5 times, especially suitable for multi variety and small batch production.

Flexible manufacturing: Quickly replace fixtures and programs, and complete welding tasks for different products on the same workstation.

Data traceability: Record complete welding parameters and process data to meet quality system requirements such as ISO/TS 16949.

Any size can be customized
D16 Specifications (LxWxH)
1000x1000x50mm；	2000x1000x50mm；
1200x1200x50mm；	2400x1200x50mm；
1500x1500x50mm；
Material:B, Q355 steel plate welding, c, high hardness steel plate welding, d, stainless steel plate welding
Aperture:A = φ16.065 -- φ16.149mm.
Hole spacing:L1=50±0.05mm。
Engraved line:The scribe pitch W1 = 50±0.05mm.
Flatness:0.1/1000mm。
Verticality:0.05/200mm。
Surface roughness:Ra3.2。
Bearing:Standard type 2T, frame type: 5T.
Hardness:Hardness of material body

Any size can be customized
D22 Specifications (LxWxH)
1000x1000x200mm；	2400x1200x200mm；
1200x1200x200mm；	3000x1500x200mm；
1500x1500x200mm；	4000x2000x200mm；
2000x1000x200mm；
Material:A, HT300 casting, B, Q355 steel plate welding, c, high hardness steel plate welding, d, stainless steel plate welding
Aperture:A = φ22.065 -- φ22.149mm.
Hole spacing:L1=100±0.05mm。L2=100±0.05mm。L3=50±0.05mm。L4=50±0.05mm。
Engraved line:The scribe pitch W1 = 100±0.05mm.
Flatness:0.1/1000mm。
Verticality:0.1/200mm。
Surface roughness:Ra3.2。
Bearing:Standard type 2T, frame type: 5T.
Hardness:Hardness of material body and nitriding layer: HV450-HV630

Any size can be customized
D28 Specifications (LxWxH)
1000 × 1000 × 200mm	1500 × 1500 × 200mm
1000 × 1500 × 200mm	1500 × 2000 × 200mm
1000 × 2000 × 200mm	1500 × 3000 × 200mm
1000 × 2500 × 200mm	1200 × 2400 × 200mm
1200 × 1200 × 200mm	2000 × 3000 × 200mm
1200 × 2400 × 200mm	2000 × 4000 × 200mm
Material:A, HT300 casting, B, Q355 steel plate welding, c, high hardness steel plate welding, d, stainless steel plate welding
Aperture:A = φ28.065 -- φ28.149mm.
Hole spacing:L1=100±0.05mm。L2=100±0.05mm。L3=50±0.05mm。L4=50±0.05mm。
Engraved line:The scribe pitch W1 = 100±0.05mm.
Flatness:0.1/1000mm。
Verticality:0.1/200mm。
Surface roughness:Ra3.2。
Bearing:Standard type 2T, frame type: 5T.
Hardness:Hardness of material body and nitriding layer: HV450-HV630