The Challenge
Automating Material Handling Around the Laser Welding Process
Laser welding was only one part of the manufacturing challenge.
Formed sheet metal panels needed to move efficiently from upstream forming equipment into the welding operation while accommodating significant variation in panel dimensions and configurations. Each panel also required multiple orientation changes so all four corners could be accurately presented for welding.
The customer needed an automated solution capable of:
- Receiving formed panels directly from upstream processing equipment
- Handling panels of varying sizes and configurations
- Automatically identifying the correct product
- Picking and reorienting large sheet metal panels
- Precisely presenting each corner to the weld fixture
- Completing four corner welds consistently
- Maintaining material flow between upstream and downstream operations
- Minimizing manual handling throughout the process
Rather than treating laser welding as a standalone operation, the complete process needed to function as one integrated manufacturing system
The Solution
A Fully Integrated Robotic Laser Welding Cell
MWES engineered a custom automation system that integrates robotic material handling, precision fixturing, laser welding, conveyor systems, product identification, controls, and safety into a coordinated production cell.
Panels enter the system from upstream forming equipment and travel through an integrated conveyor buffer before reaching the robotic welding cell. From there, automation manages the panel throughout the welding process—from initial pickup through finished-part discharge.
Robotic Panel Handling & Reorientation
A FANUC R-2000iC/210L industrial robot equipped with a dynamic vacuum end-of-arm tool (EOAT) picks formed panels from the incoming conveyor.
The robot transfers the panel to a reorientation stand, changes its grip position, and then presents the panel to the weld fixture in the orientation required for welding.
The dynamic vacuum tooling provides the flexibility needed to accommodate multiple panel dimensions while maintaining controlled, repeatable handling.
Precision Laser Welding
A FANUC LR Mate 200iD robot integrated with a DNE laser welding system performs the automated corner welding operation.
Once the material handling robot presents the first corner, dedicated tooling clamps the weld joint into position. The welding robot completes the weld before the material handling robot advances the panel to the next joint.
The process continues until all four corners are welded, with the material handling robot rotating and repositioning the panel automatically between welds.
Flexible Product Handling
The system is designed to accommodate a wide range of formed panel configurations, including variations in width, length, depth and orientation.
Operators can select the appropriate panel configuration through the HMI or use barcode identification to determine the product entering the robotic cell.
This recipe-driven approach provides the flexibility to automate multiple products within the same system without requiring a dedicated welding cell for every panel configuration.
Integrated Material Flow
MWES integrated the laser welding operation directly with the surrounding manufacturing process.
Multiple conveyor sections create an upstream buffer between the panel-forming equipment and welding cell, helping maintain consistent product flow. Once welding is complete, the robot automatically transfers the finished panel to the outbound conveyor for downstream handling or palletizing.
By integrating material movement with the welding process, the system minimizes operator involvement between production stages.
Complete System Integration
MWES provided the mechanical engineering, electrical engineering, robotic programming, controls integration, HMI development, system assembly, testing, startup, and training required to bring the complete automation system together.
The result is more than an automated welding station—it is an integrated manufacturing solution engineered around the customer’s complete process.
The Results
Automated Material Flow, Consistent Welding & Greater Production Flexibility
The completed system brings material handling and laser welding together into one coordinated automation process, reducing the manual intervention required to move, orient, position, and weld large sheet metal panels.
Key outcomes include:
- Automated handling of panels up to 144 inches long and 120 pounds
- Robotic reorientation eliminates manual manipulation between welds
- Automated welding of all four panel corners
- Reduced manual material handling between forming and welding operations
- Consistent robotic positioning at each weld location
- Flexible processing of multiple panel sizes and configurations
- Barcode and HMI-based product selection
- Integrated upstream buffering and downstream material transfer
- Automated transfer of completed panels for downstream processing
- One coordinated controls platform connecting material handling, welding, conveyors, and safety
By engineering the automation around the entire manufacturing process—not just the weld itself—MWES created a flexible system that connects upstream production, robotic material handling, laser welding, and downstream operations into a streamlined workflow.
