How AI is Transforming Robotic Welding Programming in Metalworking Sector

GeniusWeldPro (GWP) programming system copyright Roboteco

For three decades, it has been the exclusive distributor in Italy and, more recently, in Spain of Panasonic. multinational's anthropomorphic robots, both for arc welding and laser welding processes. By leveraging the most advanced software from its Japanese partners, Roboteco-Italargon is able to offer companies the best technological solutions and design customized systems tailored to each client’s specific needs.

The flagship of Panasonic technology, still unmatched nearly 20 years after its introduction to the global market, is TAWERS (The Arc Welding Robot System), an exclusive system that completely revolutionizes the concept of robotic welding.

Unlike conventional systems, where the robot’s CPU and the welding machine’s CPU communicate to execute welded joints, in the TAWERS system, a single CPU oversees and synchronizes all the elements involved in the welding process: the robot, the welding machine, and the wire feeder. This means that the robot controller has real-time access to all process variables.

Successful Case History

A recent application features Nexlam S.r.l., a young, dynamic, and technologically advanced company located in the heart of the industrial area of Castel Goffredo (Mantua), with over seventeen years of experience in metal sheet machining of stainless steel, carbon steel, aluminum, and brass. In a short time, it has enhanced its know-how and resources; its staff’s expertise ranges from laser cutting to punching, as well as mechanical machining, bending, welding, finishing, and assembly.

The welding and spot welding department, equipped with 10 workstations, is highly specialized in assembling all types of sheet metal components using MIG, MAG, TIG, and resistance spot welding technologies. Nexlam S.r.l. is undoubtedly a key player, capable of delivering high-quality, technologically advanced products. In its sector, metal fabrication, where efficiency and quality must go hand in hand, the company faced the need to optimize its production process. Specifically, the goal was to reduce the reliance on skilled operators for repetitive welding operations, allowing them to focus on more strategic activities. This need became even more pressing in a context marked by a growing shortage of specialized labor, a challenge affecting many companies in the industry.

Given this scenario, the company decided to explore automation solutions that could enhance productivity without compromising work flexibility.

Drawing on its experience and with a forward-looking approach, Nexlam S.r.l. identified the WILL (Welding Innovative Light Line) mini welding cell, offered by Roboteco-Italargon, as the ideal solution to meet its needs for efficiency, flexibility, and automated process management. This system proved to be the perfect tool for maximizing productivity and improving the quality of welded joints. Additionally, thanks to its compact dimensions (3.2 x 2 m), it was easily integrated into the workshop without requiring a reorganization of the production layout, ensuring a more efficient use of space.

The chosen mini welding cell model features a dual turntable with a manual station switch, enabling optimal welding operations management. The 600 mm rotation enhances flexibility and precision in component positioning. With a 1000 mm distance between fixture pin-pin and a payload capacity of 150 kg, the system can handle large workpieces, ensuring high capacity and versatility in production.

An added value of this compact solution is undoubtedly the presence of a Panasonic anthropomorphic robot equipped with the renowned TAWERS technology.

WILL stands out for its ease of use, offering a “ready-to-weld” setup simply by connecting the utilities. Its quick palletization and easy transport make it a practical and versatile solution. Additionally, the integrated Panasonic system enables precise control of welding parameters, ensuring optimal management of every stage of the production process.

In line with its Smart Factory 4.0 vision, Nexlam S.r.l. has enhanced its Panasonic robot-equipped mini welding cell by implementing the advanced GeniusWeldPro (GWP) programming system. This cloud-based software leverages Artificial Intelligence and generative algorithms to optimize the programming process.

The main reasons behind Nexlam S.r.l.’s decision to integrate GWP were twofold: the ability to significantly reduce welding robot programming times and the user-friendliness of the software, making it accessible even to less experienced personnel with minimal training.

This tool, used daily at Nexlam S.r.l., employs AI to analyze 3D CAD models, automatically identifying optimal weld joints and suggesting the best operational sequences to reduce cycle times. Thanks to GWP, the company has improved weld quality and achieved greater efficiency with a smoother, simplified workflow.

Operators upload the 3D CAD model directly into GWP, which autonomously generates the robot’s welding positions and transitions. In just a few steps, they can transfer the results to Panasonic’s DTPS (Desktop Programming & Simulation System) software, sending the carefully developed program to the robot, ready for execution. DTPS enables offline creation and modification of programs and direct CAD data import. With its collision detection and welding time calculation features, it maximizes process efficiency and safety, providing tools for motion sequence creation and optimization without halting production.

Confirming the strength of this investment, the client had the opportunity to test the system through practical trials conducted by specialized technicians at the Roboteco-Italargon Technical Center in Genoa. These tests demonstrated the quality and efficiency of the solution.

For its first investment in an automated welding system, the Mantuan company sought a cost-effective solution that would allow it to experiment with automation. The “Will and GWP” plug-in solution enabled Nexlam S.r.l. to gain greater versatility, efficiently managing even small production batches. This, in turn, allowed the company to enter sectors with high-quality standards and repetitive production, such as road transport manufacturing. With this solid foundation, the company can look to the future with prospects of further technological advancements and enhanced competitiveness in the industry.

The partnership between Nexlam S.r.l. and Roboteco-Italargon has proven to be the perfect fusion of vision and innovation, demonstrating how technological choices can drive progress while embodying the philosophy of the Mantuan company: "It's written Nexlam, it's read the future of sheet metal." This principle is reflected in its constant commitment to optimizing production processes and adopting cutting-edge solutions, opening new growth opportunities and generating value with a forward-thinking approach.