Highly flexible robot welding cell for maximum output

Robot duo masters 1,000 variants

Axles and frames for utility trailers, campers and mobile homes from AL-KO Vehicle Technology are among the best available on the market. Manufacturers all over the world place their trust in these components. Correspondingly high are the demands placed on welding technology, including first-class seam quality and highly flexible systems engineering with robots that operate with precision and process reliability. 

The AL-KO Vehicle Technology Group is a global technology group. With high-quality body and chassis components for trailers, recreational and utility vehicles as well as construction and agricultural vehicles the group is a hallmark for best functionality, highest comfort and innovations for better handling safety. With a workforce of over 3,800 at 30 locations worldwide, the group reports an annual turnover close to a billion US dollars.

Despite the globalization and expansion of this successful company, the proven AL-KO trailer components – from overrun devices to the complete axle – are traditionally manufactured at its head office in the Swabian town of Kötz.

In particular the welds in frame manufacturing are subjected to high dynamic loads, and connecting these components is among the most demanding tasks in joining technology. A reliable welding process and state-of-the-art systems engineering are indispensable here, in order to guarantee maximum component quality while maintaining unrestricted flexibility.

For the manufacture of cross members for utility trailers with an overall weight of up to 3.5 tonnes AL-KO uses a new, pioneering welding cell in which two Motoman robots are engaged in parallel welding. The overall development of the welding cell is a joint project of AL-KO and Yaskawa. The starting point was a standardised specification by the Swabian manufacturer which predefined the key parameters, including energy efficiency, safety technology, process times and quality standards.