Robotic Multi-Vane Rotor Welding System
Project OVERVIEW
Midwest Engineered Systems (MWES) designed and integrated a fully automated robotic welding system for producing multi-vane rotor assemblies. This custom solution utilizes an ABB IRB 800 industrial robot mounted on a servo-driven track for extended reach, paired with advanced positioners to handle complex geometries.
The system enables a single operator to oversee the entire process, reducing labor requirements, increasing throughput, and ensuring weld quality that meets strict industrial and aerospace manufacturing standards.
The Challenge
A global manufacturer of large-scale industrial components needed to automate the welding of multi-vane rotor assemblies—a task that had been slow, labor-intensive, and difficult to standardize with manual welding. Key challenges included:
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Complex geometries requiring multi-axis positioning for precise weld placement.
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Consistency issues due to variations in manual welding techniques.
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High labor costs and difficulty finding skilled welders.
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Integration with existing fixtures and workflow to minimize downtime.
The customer sought a robotic welding solution that could increase productivity, reduce scrap, improve safety, and deliver repeatable, high-quality welds.
The Solution
MWES engineered a robotic welding cell built around an ABB IRB 800 robot traveling on a servo-driven track to access all weld points along the large rotor assembly. The cell includes:
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Dual-Axis Servo-Driven Positioner – Fully manipulates the part for optimal weld angles.
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Precision MIG Welding System – Ensures consistent, high-strength welds across all joints.
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Advanced Safety Features – Including light curtains, operator load stations, and interlocked access points.
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HMI Interface – Allows operators to load part programs, verify components, and monitor cycle progress.
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Integration with Existing Equipment – Designed to work with the customer’s current handling and inspection systems.
Once the part is loaded into the fixture and verified via sensors, the system automatically performs the weld sequence, adjusting positioning as needed for each joint.
The Results
By implementing this custom robotic welding solution, the customer achieved:
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Up to 40% Increase in Throughput – Higher production capacity with consistent cycle times.
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Reduced Scrap and Rework – Weld consistency eliminated common manual errors.
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Lower Labor Dependence – One operator can manage the system instead of multiple skilled welders.
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Improved Workplace Safety – Reduced exposure to weld fumes, heat, and repetitive strain.
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Rapid ROI – Savings in labor, scrap reduction, and improved productivity delivered a fast payback.
Why Choose MWES for Robotic Welding?
With over 30 years of automation expertise, MWES designs turnkey welding automation systems that are tailored to each customer’s production environment. Our capabilities include:
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MIG, TIG, Laser, and Resistance Welding Automation
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Multi-Axis Positioners for Complex Assemblies
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High-Precision Fixtures and Tooling
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Robot Programming, Testing, and On-Site Commissioning
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Ongoing Service, Support, and Training
Client Details
A manufacturer of industrial components based in Illinois.