The Challenge
Scaling Welding Capacity Across Multiple Rotor Configurations
The customer struggled with:
- A shortage of skilled welders, limiting production capacity
- Manually intensive vane-to-shaft assembly and welding
- Multiple rotor and blade variants needing different weld programs
- Desired system operation by a single operator with minimal training
MWES was selected to design a flexible, single-operator solution capable of reliably welding multiple configurations using recipe-controlled automation. mwes.com+11mwes.com+11mwes.com+11
The Solution
Multi‑Robot Tandem Welding Cell with Automated Positioning & Operator Workflow
MWES engineered a welding cell featuring:
- Two ABB robots performing tandem welding of rotor vanes
- Third ABB robot loading blades onto the rotor shaft
- Ferris-wheel-style fixturing to allow operator loading and automated welding cycles
- Barcode-based HMI interface to select part-specific weld programs
- Standard safety features including mesh fencing and light curtains
Operators load rotor and vane assemblies, scan the job code, and the system automatically cycles through welding while minimizing operator exposure and eliminating guesswork. mwes.com+4mwes.com+4mwes.com+4
The Results
Improved Throughput, Reduced Labor and Enhanced Part Consistency
The automated cell delivered substantial benefits:
- Enabled a single operator to run multiple part configurations
- Improved weld quality consistency across varied rotor assemblies
- Reduced production downtime with recipe-driven automation
- Simplified setup and operation, enabling fast part changeovers
This MWES solution reliably supports high-mix rotor assembly operations while reducing labor dependence and improving throughput.
