Robotic Welding Cell
Context
problem
In manual welding of serial parts, quality variations, rework, and takt losses occur due to multiple repositioning and reorientation steps. The client, TV Gas (Yambol), welds parts requiring two seams at 180° and 90° rotations, followed by a third seam on a separate table—a process that is labour-intensive for the operator and sensitive to positioning errors. A sequenced, traceable flow is needed—pallet → welding → palletising—with secure gripping, repeatable orientations, minimal idle time, and clear ownership of the cycle.
Approach
Solution
Bullitt Robotics designed a robotic welding cell for TV Gas that standardises the entire cycle: a pallet is loaded into the cell with a pallet truck; a handling robot with a pneumatic gripper picks the part through its central opening, rotates it 180° and 90° for the first two welds, then places it on a welding table where the welding robot performs the third seam. Meanwhile, the handler prepares the next part, ensuring parallelism and a continuous flow. Finished parts are palletised automatically; the system is operated via remote control. Indicative cycle time: ~420 s/part, with high repeatability and reliability.
Parallel flow and shorter takt time
The handling robot prepares the next part while the welding robot is working, reducing idle time and shortening the overall cycle.
Secure gripping and precise orientation
The pneumatic gripper clamps through the central opening and provides accurate 180°/90° rotations for stable first welds.
Repeatability and less rework
A standardised sequence and third seam on a fixed table ensure consistent parameters, lower rework, and higher first-pass yield (FPY).
Technical specifications
Innovative robotic welding technology
The robotic welding cell is a high-efficiency, innovative system designed to automate the welding process. Key technical specifications include:
| Characteristic | Description |
|---|---|
| Client | TV Gas Ltd., Yambol, Bulgaria |
| Completion date | 05.07.2023 |
| Main components | Handling robot, welding table, pneumatic gripper |
| Welding operations | First two seams with 180° and 90° rotations, third seam on a table |
| Welding time | 420 seconds per part |
| Control | Remote control of the handling robot |
| Part fixturing | Pneumatic gripper |
| Work cycle | Continuous cycle until all parts in the pallet are welded |
For more information, you can download the robotic welding cell brochure from the link below:
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