Custom Welding System for Steel Frame Assembly

A customer in the electrical industry needed a tailor made welding system capable of manufacturing their frame assembly. This assembly is used within a rack frame. Banner Welder was commissioned to build a solution utilizing MIG and GMAW processes. Employing a semi-automatic system, the robotic welding cell featured a range of advanced functionalities, including 500 Amp .045" air cooled Tough Gun torch, a servo controlled part positioner, DX100 controller, barrier guarding, and Motoman material handling robot to attach the finished frame to the rack. The system welds CR steel while maintaining a tight +/-.050” tolerance, and part present switches are incorporated for in process integrity testing. This system has a cycle time of 74.5 seconds per frame.

The welding and material handling cell was finished in safety blue paint, and furnished to the customer. For more information about this fully equipped robotic welding system, or the full line of products and services available at Banner, please contact us directly.

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Welding System Case Study Highlights

Case Study Name
Frame Assembly
Case Study Description
This frame assembly is used within a Rack frame.
Capabilities Applied/Processes
MIG Welding
Gas Metal Arc Welding (GMAW)
Material Handling
Equipment Used to Manufacture Part
Robotic MIG Welding / Material Handling Cell
Tightest Tolerances
+/- .050"
In Process Testing/Inspection Performed
Industry for Use

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