Heavy Equipment Welding Cell Increases Output 3x

Project Overview

Heavy equipment manufacturing presents unique automation challenges. Parts are large, heavy, and require extensive welding—often hundreds of linear inches per assembly. A leading excavator manufacturer was struggling to meet production targets while maintaining quality standards.

Each excavator boom required over 200 linear inches of structural welding, taking skilled welders 4+ hours per unit. With demand exceeding capacity and skilled welders in short supply, the manufacturer turned to AMD Automation for a solution.

Engineering for Heavy Fabrication

Automating heavy fabrication requires specialized equipment and engineering:

Custom Positioner Design

Standard welding positioners max out at a few hundred pounds. For 5,000 lb excavator booms, we designed a custom 3-axis servo positioner with: - Heavy-duty roller bearings rated for continuous operation - Servo drives with position feedback for ±0.1° accuracy - Integrated safety interlocks for part clamping verification

Extended-Reach Robots

The FANUC M-710iC/50 robots provide the reach and payload needed for heavy fabrication: - 2,050mm reach to access all areas of large weldments - 50 kg payload for heavy torch packages - IP65 rating for weld spatter resistance

Multi-Process Capability

Different joint configurations require different welding approaches. The Fronius TPS systems switch automatically between: - CMT (Cold Metal Transfer) for root passes with minimal distortion - Pulse MIG for high-deposition fill passes - Standard short arc for specific joint types

Offline Programming

Programming 200+ inches of weld paths directly on the robot would require days of teaching time and halt production. AMD Automation implemented offline programming using:

Digital Twin Simulation

Complete cell geometry imported into ROBOGUIDE allows programmers to develop and optimize weld paths without interrupting production.

Automatic Path Generation

CAD-to-path software generates initial weld paths from 3D models, then programmers optimize torch angles and travel speeds.

Virtual Validation

Complete simulations verify reach, collision avoidance, and cycle time before downloading to the robots.

New boom variants can now be programmed in days rather than weeks.

Customer Testimonial

"We didn't think automation was possible for parts this big and complex. AMD Automation proved us wrong. The cell paid for itself in 18 months, and we're finally able to keep up with customer demand."

— Manufacturing Manager, Heavy Equipment Manufacturer