Welding Fixtures

No Welding Automation is Complete without Welding Fixturing

One of the most important keys to success in designing and building automated robotic welding systems is the ability to properly hold pre-tacked assemblies or capture multiple components for welding. Additionally, the infinite variety of possibilities for a weldment’s shape, size and weight requires unique, custom-engineered fixturing solutions for each application. Midwest Engineered Systems engineering capabilities give us the ability to design robust fixtures for welding automation projects regardless of the complexity and deliver a turn-key production line integrated solution.

Automated welding fixtures do more than just secure and position the workpiece, they can handle workpieces to a predetermined acceptable tolerance and work within precise system dimensions. Welding fixtures make it easier to rapidly perform welding operations on parts with consistently high standards of quality for the entire welding process. By using automated weld fixtures, the overall production costs can be lowered and the work environment be made safer for the system operator.

Utilizing weld fixtures allows machines to take on physically demanding, hazardous and repetitive tasks. Industrial robotic systems can go beyond human limitations in terms of load-bearing, speed, precision, endurance, size of materials and strict adherence to a set of task directives. There are several ways welding fixtures can be controlled in an automation system including hydraulically, with pneumatics as well as the more common servo drive systems. Weld fixtures are ideal when welding large steel trusses, structural framing, large cylinder assembly, and steel framing for data center servers.

Hydraulic Welding Fixtures

Hydraulic welding fixtures use hydraulic fluid to power clamps or grippers to reliably hold machine parts and other metals that will be welded together. Using hydraulics with welding fixtures permits a level of robotic precision and highly repeatable part positioning that just isn’t possible with manual welding fixtures. Automated hydraulic welding fixtures run dependably and are capable of holding parts without causing metal distortions while offering trustworthy repeatability.

Pneumatic Welding Fixtures

Pneumatic welding fixtures work through air-actuated cylinders that provide the holding pressure a fixture uses to clamp the components to be welded down. These types of clamps are well-suited for repetitive, high-speed operations. Sealed clamps are the pneumatic welding fixtures of choice for heavy welding jobs that require a high degree of clamping capability. Pneumatic welding fixtures are used to weld parts in the food, aerospace and automotive industries. It also has applications in CNC machining, fixturing, testing and welding.

Manual Welding Fixtures

Manual welding fixtures are designed to allow welders to manually handle weld components. Manual welders with the proper training and certification can work with different types of stainless steel, carbon steel and aluminum materials. To maximize efficiency, welding workstations should be ergonomically designed and possess sufficient spacing and other safety features to minimize the chance of workplace accidents or equipment damage. Robotics combined with manual welders can productively split the welding-related labor: automated processes can handle repetitive and/or physically strenuous welding tasks, while manual welders can handle highly specialized tasks. Both types of welding are used in utility-scale racking systems, construction, the automobile industry, and the field of renewable energy.

Our highly experienced engineering team understands the benefits and drawbacks of each type of welding fixture and utilizes their extensive knowledge base to determine the best control technology for the automated weld fixtures we integrate into new automation systems. If your welding process is transitioning over to robotic automation then welding fixtures are a necessity. Contact us today and speak with one of our applications engineers and they can help guide you through the process.