Robotic Welding Cells for Turnkey Automation
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Robotic Welding Cells: Turnkey Systems That Get You Welding Faster
A robotic welding cell is a complete, integrated welding system that packages the robot, or manipulator, welding power source, torch, wire feeder, fixturing, positioner, safety enclosure, and controls into a turnkey unit. This creates a ready-to-weld environment with minimal custom engineering.
Pre-engineered weld cells reduce deployment time and cost, when compared with fully custom systems, by using standardized designs that cover the majority of common welding applications. These welding cells still allow for configuration of specific workpiece sizes and weld requirements.
A well-specified weld cell eliminates the integration risk of assembling components from multiple vendors. The robot, power source, torch, welding positioner, and safety systems are designed and tested to work together in a pre-engineered weld cell. This reduces commissioning time and troubleshooting complexity.
Capital Machine Technologies, through Capital Robotics, is the provider of Fusion Arc robotic welding cells. This is a proprietary robotic welding system built with common-base construction for fast deployment and integrates OTC Daihen & Yaskawa Motoman manipulators with Welbee and Miller power sources. This complete system integration improves welding operations for welders.
Custom Solutions
Fusion Arc Weld Cells: Our Complete Lineup from Compact to Heavy-Duty
Capital Machine offers a full product lineup of its Fusion Arc Welding System. We offer small to large cells that cover all your arc welding needs. Our Fusion Arc 180L and 200L models offer extended work envelopes compared to standard counterparts. This accommodates larger or longer workpieces without stepping up to a completely different cell platform.
Fusion Arc Welding System
- Fusion Arc 100: A compact cell for smaller workpieces and entry-level robotic welding.
- Fusion Arc 180 and Fusion Arc 180L: Mid-range cells with standard and large work envelope options. Open station options for larger parts.
- Fusion Arc 200 and Fusion Arc 200L: Same side loading keeps the automation running for higher production volumes.
- Fusion Arc 300: Best use of robotic arm envelope. Utilizes multiple stations for the high-mix/low-volume applications.
Fusion Arc cells are designed for rapid assembly and deployment making the welding process much more efficient. The slot-and-tab configuration allows the cell to be shipped flat and assembled on-site quickly, reducing installation time compared with fully welded enclosure designs.
Capital Machine also offers the Opti-Cart, a mobile welding solution, for shops that need flexible placement or want to move welding capability between stations. This is ideal for facilities with space constraints or evolving production layouts.
All our Fusion Arc models integrate with dedicated welding manipulators from OTC Daihen & Yaskawa Motoman. We pair these up with application-specific power sources by OTC Daihen, Welbee, Miller Welding, Auto-Continuum power sources, plus others. This ensures peak performance across the robot, arc control, and cell configuration.
How Robotic Welding Cells Deliver ROI for Job Shops and Production Manufacturers
Robotic welding cells are precision instruments that typically deliver ROI within 6 to 24 months, depending on production volume, labor market conditions, and weld complexity. The strongest returns will be found in weld intense applications, repeatable welding applications.
Robotic welders offer significant ROI as robotic cells can achieve 80%+ arc-on time versus less than 15% for manual welders. A welding robot in a dual-station well cell also offers reduced labor cost per part as one operator can load and unload parts on one side, while the robot welds on the other. Robotic welding offers improved weld consistency with fewer rejects, less rework, and reduced consumable waste. The American Welding Society estimates a shortfall approaching 360,000 welders by 2027. Robotic welding cells provide a scalable solution that doesn't depend on finding and retaining skilled manual welders.
Capital Machine can help shops make the transition through its consultative process, which includes a ROI analysis for prospective robotic weld cell customers. We help shops evaluate current labor costs, production volumes, and quality metrics to quantify the expected return before purchasing.
Which Industries Use Robotic Welding Cells and What They're Producing
Many industries are deploying robotic welding cells. Automotive and automotive suppliers use robotic welding cells for high-volume bracket, frame, and chassis welding. Heavy equipment and agricultural manufacturing use robotic welding automation for structural welds on thick-plate components. HVAC uses welding robots for repetitive enclosure and ductwork welds. Construction uses robotic welding cells for structural steel connections, while the oil & gas industry uses it for pipe and vessel fabrication.
The best candidates for robotic welding cells share several common traits: repeatable joint geometry, consistent part fit up, sufficient production volume, and accessible weld joints. Shops that meet these criteria see the fastest payback. Dual-station weld cells, where one side is being loaded and unloaded, while the other side is welding, offers maximize productivity by eliminating idle time between parts. This is a configuration available across our Fusion Arc Welding System lineup.
Capital Machine's regional industry expertise helps match the right robotic welding cell configuration to local manufacturing needs, such as Dallas, Texas for oil and gas, the Midwest for automotive and agricultural, and the Southeast for general fabrication.
Installation, Programming, and Lifecycle Support for Your Weld Cell
Capital Machine offers full lifecycle support. We handle application review and cell specification, a pre-install site survey, delivery and assembly, calibration and first-article testing, operator and programmer training, and production ramp-up support.
We also offer teach pendant programming for initial weld path creation, offline programming software for developing programs without stopping production, and weld schedule optimization to fine-tune parameters for each material and joint type. Lead-through teaching is also available through collaborative options.
Capital Machine's lifecycle support model includes condition-based maintenance programs, application support for new part programs, break-fix service with parts-stocked vans, and system retrofits as production requirements evolve. We offer positioner upgrades, power source changes, and torch replacements as well.
Our 40+ full-time, factory-trained field service engineers across our 22-state territory are always here to service your shop's needs. We employ no subcontractors providing the largest dedicated service staff of any metal fabrication equipment distributor in the South. Learn more about our service options.
Explore Robotic Welding Cells: Request a Consultation
Capital Machine offers shops a consultative approach. Every engagement begins with understanding your welding challenges, production goals, and facility constraints. We then specify the right Fusion Arc cell configuration with matched Yaskawa manipulator and OTC Daihen power source for your shop's specific needs.
We invite manufacturers to visit our 5 technology centers located in Tampa, Florida; Atlanta, Georgia; Dallas, Texas; Indianapolis, Indiana; and Harrisburg, Pennsylvania to see our Fusion Arc weld cells and robotic welding systems in operation. You can discuss applications with our technical staff and evaluate configurations firsthand.
Capital Machine's robotic weld cell capabilities are available through our Capital Robotics division. We combine our proprietary Fusion Arc Welding System with Yaskawa robotics expertise and the full Capital Machine service infrastructure to attend to your needs.
Contact Capital Machine today to schedule a consultation about your robotic welding cell needs. Whether you're automating your first welding process, replacing an aging cell, or expanding your robotic welding capacity we can help. Contact us today.