Adaptive welding for Metal Structures
Repeatability, precision and quality in structures
Metal Structures
In structural applications, Smart Robotic Welding, a solution by CADE, is aimed at large structures and large-scale components such as built-up beams, housings and high-volume assemblies, where automation provides precision, repeatability and process control in highly demanding welds.
Smart Robotic Welding adapts to butt joints, fillet joints and lap joints, continuously adjusting to the real geometry of the product. The system corrects the trajectory and working parameters according to the actual conditions of the part, even when deformations occur during the welding process itself. This makes it possible to maintain process quality and stability in large structures.
Thanks to the effectiveness of Smart Robotic Welding tracking, it is possible to work at welding speeds far higher than those that can be maintained through manual visual control. In certain applications, this enables speeds of up to 1 metre per minute, while maintaining process stability and weld bead quality.
Capabilities
Smart Robotic Welding
The smart adaptive welding of Smart Robotic Welding combines 3D vision, dynamic adjustment algorithms and adaptive arc control to perform welds with a high level of precision and stability in large structures.
The system identifies the real geometry of the joint and continuously adjusts the trajectory, torch orientation and welding parameters during the process. This makes it possible to maintain weld bead geometry and uniform penetration even when there are variations in the joint position or deformations during the welding process itself.
As a result, Smart Robotic Welding provides high repeatability between weld beads and greater consistency in working parameters, resulting in a homogeneous finish quality throughout the entire manufacturing process.
Applications in Structures
Smart Robotic Welding is ideal for structures such as:
- Lightweight frames and chassis: SRW performs weld beads on multiple or angular joints with adaptive thermal control. It is ideal for industrial equipment frames, robotic structures or internal transport systems, where dimensional precision and high repeatability are required.
- Support structures and racks: Repetitive welds on thin profiles, where rigidity, parallelism and weld bead aesthetics are essential. The smart robotic welding of SRW ensures uniform weld beads, reduces warping and maintains constant tolerances throughout the entire production process.
- Precision frames: In structures that integrate mechanical or electronic components, weld bead accuracy is critical for correct assembly. SRW maintains precise tolerances, compensating for deviations through 3D joint tracking and adaptive control, achieving a uniform, high-quality aesthetic finish.
- Metal housings and covers: In thin sheets or enclosure structures, SRW makes it possible to weld parts with high visual quality, without distortion or overheating. Its smart thermal control reduces subsequent adjustment times and improves productivity in light boiler making parts.
- Modular and auxiliary structures: Perfect for serial assembly or production-line manufacturing. The smart welding of SRW ensures identical weld beads across batches, with full digital traceability and real-time supervision, optimising every repetition of the process.
- Large structures: SRW also proves highly effective in built-up beams, reinforcing rings, frames and large-format structural frameworks, where welding speed and system autonomy provide a very significant saving in total manufacturing time. Its adaptive tracking capability makes it possible to maintain consistent quality even in long weld beads or complex positions, reducing the need for rework and ensuring higher productivity in large components.
Real-time Smart Welding for industrial processes
To see Smart Robotic Welding in action, request a demo and discover how real-time smart welding can optimise your industrial processes.