Robotic Complex for Laser Surface Hardening, Hybrid Laser-Arc Cladding, and Hybrid Laser-Arc Welding
This complex is universal and designed for surface hardening (quenching), welding, and surfacing of metal surfaces using a modern fiber laser and digital welding equipment for gas-shielded welding, with real-time video process control.
The complex consists of a fully enclosed thermal chamber with a universal workstation up to 12 m long and 2 m wide. Tool movement is performed by an industrial robot with enhanced payload capacity and precision. The robot is equipped with two tools: a laser head with a laser beam oscillation system and a MIG/MAG welding torch.
The universal workstation includes a positioner with a rotary table and three-jaw chucks, a tailstock, steady rests, and a mobile welding table. Above the movable work area is a fume extraction system providing ventilation throughout the operation of the complex.
Complex and Workstation Layout
A — complex plan, B — workstation layout
- Laser source
- Movable welding table platform
- Robot carriage equipment platform
- Automation control cabinet
- Cooling unit
- Voltage stabilizer
- Operator table
- Screw compressor
- Laminar cabinet
- Gas cabinet
- Industrial robot
- Positioner
- Fume extraction system
System Components
Industrial Robot Manipulator with Optical Scanning Head and Welding Torch
Mechanism type — 6-axis robot
Longitudinal movement axis — 1
Maximum payload — 70 kg
Working radius — 2050 mm
Positioning repeatability — ±0.04 mm
Minimum movement speed — 1.5 m/min
Fronius TPS 400i Welding Power Source
Cooling type — liquid
Welding current range — 3–400 A
Welding current at 10 min / 40°C (duty cycle 40% / 60% / 100%) — 400 / 360 / 320 A
Wire diameter — 0.8–1.6 mm
Workpiece Positioning System
Expandable tailstocks — 3
Tailstock — 1
Worktable dimensions (L×W) — 2600×1100 mm
Guide system length — 12 m
Three-jaw chucks — 3 pcs
Clamping diameter — 5–800 mm
Protective Cabin
Dimensions (L×W×H) — 18,000×5100×3100 mm
Dome camera — 1
Built-in Coaxial Video Camera
Automation Control Cabinet with User-Friendly Interface
Examples of Complex Operation
Two-layer laser cladding (layer thickness 2 mm)
Single-pass welding, edges without bevel or gap
Three-pass welding, edges with 30° bevel and 1.2 mm gap
Surface laser hardening (track width from 4 to 25 mm)
Gallery of completed projects
