Commissioning of a robotic welding line
About the project
For a German Tier 1 supplier we took over the complete commissioning of a six-robot welding cell — from mechanical assembly to handover.
Siemens S7-1500 control system with PL d safety architecture, Profinet / Profisafe communication, WinCC visualisation. Achieved cycle time of 42 seconds per part at the required weld quality.
The project also included optimisation of robot paths and cycle tuning together with the customer's process engineers.
Brief and challenge
The customer needed to start a new welding cell on a fixed series-production ramp-up date, with a guaranteed cycle time and PL d safety level.
Our solution
- Taking responsibility for the entire commissioning — one partner instead of three suppliers.
- PL d safety architecture designed and tested before arriving on site.
- Robot path optimisation and cycle tuning directly with the customer's process engineers.
- Training of operators and maintenance including fault-state documentation.
Project course
- 01
Assembly and electrical
Mechanical assembly of the cell, cabling, wiring of drives and safety components.
- 02
Programming
Siemens S7-1500 PLC, FANUC robot programs, WinCC visualisation.
- 03
Commissioning and SAT
Step-by-step commissioning, safety tests, cycle tuning and handover.
Result
- Handed over on the series-production ramp-up date.
- Stable cycle of 42 s per part at the required weld quality.
- Safety functions verified and documented to PL d.
We share detailed project parameters on request, to the extent permitted by our contractual arrangements with the customer.