System Overview
Industry: Building Materials Equipment Manufacturing
Key Results: 35% Cycle Time Reduction · 36 Welds Fully Automated · 3 Operators Saved
Description:
AGR Robotics delivered a fully automated robotic welding and bending workstation to a leading building materials group.
The system integrates robotic handling, arc welding, and bending operations, supporting 11 hopper specifications.
It automates the full process — from assembly and positioning to welding and bending — significantly improving production efficiency, cycle time, and weld consistency.
Client Background
The project was delivered to a leading domestic manufacturer of conveyor system components in the building materials industry.
The client’s objectives included:
• Improving weld consistency and accuracy across multiple hopper types
• Reducing cycle time while maintaining structural precision
• Lowering manual labor dependency through automation of bending and welding operations
Project Challenges
• Complex product geometry: 11 hopper models required repeated manual repositioning and fixture changes.
• High welding quality requirements: Dozens of seams demanded uniform penetration, minimal spatter, and tight tolerance.
• Manual bending bottlenecks: Conventional bending was operator-dependent, slowing production and reducing repeatability.
AGR Solution
• AGR designed a multi-functional robotic workstation, integrating handling, arc welding, and bending in one cell.
• Custom-designed fixtures and electromagnetic floating grippers were developed to fit all 11 hopper variants seamlessly.
• Vision-guided alignment enabled precise positioning and smooth pre-assembly.
• Added automated wire cutting, torch cleaning, and offline programming standardization to ensure long-term stability and easy maintenance.
System Composition
• Welding Robot: FANUC M-10iD/8L six-axis robotic arm
• Welding Power Source: LINCOLN Power Wave E500 digital arc system
• Handling Robot: FANUC M-900iB/360 for part transfer and repositioning
• Tooling & Positioning: Three-jaw electric chucks, multi-axis positioners, and automatic clamping modules
• Auxiliary Systems: Vision recognition unit, automatic wire cutter, torch cleaning station, PLC control cabinet, and hydraulic lifting platform
Project Timeline & Current Status
• Delivered in mid-2023, the system has been operating reliably for over 12 months with verified uptime exceeding 98%.
• The client reports consistent productivity gains, stable weld quality, and reduced maintenance intervals, confirming AGR Robotics as a trusted automation partner in the building materials sector.
