Task: Automation in the face of a shortage of skilled workers and high variant diversity
Industrial production is under increasing pressure: the availability of qualified specialists is decreasing, while at the same time the requirements for quality, process reliability and flexibility are increasing. Manual handling quickly becomes a bottleneck, especially when it comes to components with many variants, different geometries and larger tolerances - both in terms of time and reproducibility.
In this specific case, the previously manual welding process for base nozzles of pressure vessels was to be replaced by an automated solution. The aim was to increase productivity, reduce dependency on operating personnel and at the same time ensure consistently high seam quality - even with frequently changing component variants.
Solution: Fully automated welding cell with integrated quality assurance
KLOTZ has developed a fully automated welding system that takes care of all the key process steps - from parts handling to quality control. At the center is a welding robot with turn-tilt positioning, which executes the circumferential seams precisely and reproducibly. A specially designed clamping device ensures the exact alignment of the components - even with larger tolerances.
A high-performance bin-picking system is used for material supply. This removes components directly from mesh boxes, automatically recognizes their position and shape and transfers them to the robot in the exact position. Manual teaching can therefore be completely dispensed with - a decisive advantage with a high number of variants and limited set-up time.
An optical inspection system is fully integrated into the process and inspects the weld seams on both sides in accordance with EN ISO 5817, replacing the previous manual visual inspection with a digital, standard-compliant and process-reliable inspection mechanism.
The result is a highly automated and stable production process with minimal operating effort - from the raw part feed to the tested assembly. The system enables reliable, efficient and scalable production - ideal for modern manufacturing companies with high requirements.
