Flexible Robotic Welding Cell

The Borunts Tech Flexible Robotic Welding Cell is a pre-configured, skid-mounted automated welding system for structural carbon steel, stainless steel, and aluminum components. Built on a stress-relieved structural steel base, it integrates a 6-axis industrial robot, dual-station servo positioners, a synergic welding power source, and an ANSI/RIA-compliant safety enclosure. Shipped as a pre-aligned, pre-wired single unit, it eliminates field installation alignment errors and accelerates cycle times for high-mix production runs.

Automotive Sub-Assemblies: Cross-members, seat frames, and suspension control arms using high-strength low-alloy (HSLA) steel.

Heavy Machinery: Hydraulic cylinder brackets and structural cabin frames utilizing thick-plate carbon steel up to 25 mm.

Enclosures & HVAC: Stainless steel junction boxes and air-handling frames requiring spatter-free TIG or pulsed MIG welding.

Mechanical Datum: Robot pedestals and positioner tooling sub-bases are machined from a single weldment, maintaining a 0.05 mm relative mechanical tolerance.

Control & Communication: EtherNet/IP and Profinet protocols link the robot controller, welding power source, and PLC. The HMI stores up to 255 unique part programs with OPC UA data export.

Maintenance Automation: Pneumatic torch cleaner station with automated reamer, anti-spatter fluid sprayer, and wire cutter operating on programmable cycle counts.

Safety Architecture: Heavy-gauge sheet steel base plates with polycarbonate/wire-mesh upper panels interlocked via dual-channel safety switches conforming to ISO 13849-1 (Cat 3, PL d/e) and ISO 10218-1/2.

Fixture Tooling: Quick-change hydraulic or pneumatic clamping sub-plates engineered from customer-supplied 3D CAD data.

Vision Guidance: 2D or 3D laser scanners mounted to the torch assembly for joint tracking on high-variance geometries.

Process Adaptability: Multi-purpose cell layout capable of quick changeovers between MIG welding, plasma cutting, or stud welding.

Machining & Stress Relief: Base frames and positioner trunnions are milled on CNC floor borers following thermal annealing and vibrational stress relief.

Electrical Compliance: Control panels are built in an ISO-compliant facility using numerical terminal labeling and wire ferrules meeting UL508A and NFPA 79 standards.

Factory Acceptance Testing (FAT): Mandatory 72-hour burn-in execution utilizing customer material coupons, verified via CMM dimensional checks prior to crating.

Pre-Shipment Documentation: Layout drawings, foundation loading diagrams, and utility schematics issued 4 weeks prior to dispatch.

Deployment & Training: Factory deployment engineers handle mechanical anchoring, utility hookup, and a 5-day on-site operator/programmer training program.

Remote Diagnostics: Secure onboard VPN router integrated into the PLC cabinet for remote ladder logic and error log troubleshooting.

Spare Parts Inventory: Critical wear components (contact tips, gas nozzles, swan necks, drive rolls) stocked for same-day dispatch.