Robotic Welding System for Crane Components
Context
problem
When welding large crane components, any deviation in geometry or root gap directly affects load capacity and safety. The client, Lit Manufacturing Kft (Pécs, Hungary), produces complex structures with Class B requirements and full penetration, which have traditionally been handled only by highly skilled welders. The manual process is slow, hard to repeat, and heavily dependent on individual skills. A system is needed that can deliver consistent quality along the entire weld, compensate for real joint gaps, and free expert welders from the heaviest and most repetitive operations.
Approach
Solution
Bullitt Robotics developed a robotic welding system built around two long-reach FANUC welding robots, each mounted on a three-axis gantry. The robots are equipped with Servo-Robot laser cameras that monitor the weld zone and adapt the trajectory and parameters in real time to the actual joint gap. This ensures full penetration and Class B quality over the entire seam length, even on large and complex parts. The system automates critical operations that previously required master-level welders and allows these experts to focus on supervision, process control, and optimisation instead of manual execution of every weld.
High-grade quality on large parts
The two FANUC robots on three-axis gantries deliver stable full penetration and Class B quality along the entire weld, even on complex crane structures.
Adaptive tracking of the weld gap
Servo-Robot laser cameras continuously monitor the weld zone and adjust the trajectory and parameters in real time to match the actual joint gap.
Automation of expert welding work
The system takes over heavy and critical welding tasks that used to require master welders, allowing them to focus on process monitoring and fine-tuning.
Technical specifications
Innovative robotic welding technology
The robotic welding system for Lit Manufacturing Kft is designed for large parts with stringent quality requirements and full penetration. Key technical specifications include:
| Characteristic | Description |
|---|---|
| Client | Lit Manufacturing Kft, Pécs, Hungary |
| Completion date | January 2025 |
| Main components | 2 FANUC welding robots, 2 three-axis gantries, Servo-Robot laser cameras |
| Welding operations | Welding of large crane components to Class B with full penetration |
| Welding time | Optimised for long seams and heavy sections |
| Control | Coordinated control of both robots and gantries |
| Part fixturing | Special fixtures for secure clamping of large structures |
| Work cycle | Automated cycle for serial welding with minimal operator intervention |
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