Robotic Welding For Forklift Mfr Facilitates Production Speed & Business Growth

Robotic Welding Cell Handles and Welds 72 Different Parts with Quick, Easy Changeover

A leading forklift manufacturer established almost a century ago needed a robotic welding solution to meet increasing demand for their industrial lift products. Their existing welding processes were labor-intensive, creating a severe bottleneck in production.

The Challenge

Slow manual weld cycles of over 72 part types slowed throughput and limited business growth during a period of strong demand.

The Solution

After a thorough analysis of welding processes, Genesis determined the best solution was to use a GenS 3XC robotic welding workcell utilizing a servo driven exchange axis to accommodate the size and weight of the welding fixtures.

The system featured a center mount robot and a robot mounted on the floor to maximize the work envelope, covering the entire length of the part.

Robot tooling consisted of both manual and pneumatic clamps with sensors to detect open and closed positions, giving the robotic welding cell the ability to handle a wide range of parts.

The Results

Genesis delivered a robotic welding cell capable of handling and welding 72 different types of parts. The system was built for fast and simple changeover between part numbers to further reduce weld time on each part.

Overall robot weld time was balanced to optimize cycle time, which was dramatically reduced to only 5 minutes per side, and each robot was set up using common programs for ease of use after implementation.

The robotic welding cell improved the accuracy and quality of welds, but most importantly, met the manufacturer’s goal of eliminating production bottlenecks in welding. The increased throughput found through automation allowed the manufacturer to keep up with increasing demand to grow their business.

Let’s Discuss Your Robotic Welding Application Requirements.

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