The Challenge
Tackling Complex Panel Welding in a Labor‑Constrained Rail Environment
Welding large corrugated steel panels with integrated framing is challenging due to part size and weld complexity. The manufacturer faced:
- High demand for large-scale panel assemblies containing embedded window frames and structural beams
- A shortage of skilled welders capable of handling this complex, repetitive work
- Need for weld consistency and throughput in a paced production cell
MWES was selected to deliver a robotic laser welding solution that combined precision, high throughput, and minimal operator oversight.
The Solution
Gantry Robot & Overhead Laser Welding Cell for Reversible Panel Welding
MWES engineered a large-scale gantry system featuring:
- A Gudel 6-axis overhead gantry robot with a laser welding head, controlled via KUKA
- Ability to process up to four wall-panel assemblies in sequence as operators load and prep each model
- Operators load stiffeners, window frames, and top/bottom corrugated panels into a clamped top frame
- System can flip panels mid-process, enabling backside weld operations
- Includes integration of vertical beam and side pillar welding post panel seam process
This automated cell enables continuous high-precision welding feed across full panel geometries with minimal manual weld labor.
Summary: The gantry-mounted laser welding system allows multiple panel assemblies in sequence, including front and back welding operations—delivering consistent, high-speed rail car panel fabrication.
The Results
Consistent Multi‑Panel Throughput with Reduced Labor and Weld Quality Assurance
The completed system provided measurable outcomes:
- Automated welding of large-scale panels in additive sequence—processing up to four assemblies per cycle
- Enabled reversible panel welding (front/back) without manual repositioning
- Freed operators from hot, repetitive welding tasks—requiring simple part loading and unloading
- Delivered consistent weld depth and quality across complex geometries
By integrating laser welding with gantry and flip capabilities, MWES helped the customer achieve high-volume, reliable panel production while aligning to labor constraints and quality demands.
