Real systems.
Real production constraints.
Documented outcomes.
Each case describes the production context, the specific constraints that shaped the system design, the engineering logic applied, and the measured results. Client names are not disclosed. The engineering is.
15-robot automated line
for crane leg bracket fabrication.
The largest single project AGR has completed. A fully automated multi-station welding line for thick-section structural crane components, delivered to one of China's top-3 crane manufacturers under a direct contract.
A leading Chinese crane manufacturer required a fully automated welding solution for crane leg structural brackets — high-strength thick-section components with demanding dimensional and weld quality requirements.
The client operated existing manual welding processes with inconsistent output and required a system capable of meeting structural inspection standards at production volume. AGR was engaged under a direct contract.
- Incoming part consistency — upstream cutting tolerance variation required real-time joint tracking compensation
- Multi-robot synchronisation across 15 units — coordinated motion without interference or production conflict
- Cross-supplier coordination — AGR's scope integrated with other vendors' equipment within the same line
- Strict client acceptance criteria — structural weld quality and dimensional tolerance verified at each station
- Production schedule pressure — line required to reach full output within agreed commissioning period
- Weld sequence and heat input designed from process analysis before system configuration — distortion control built in at design stage
- Laser seam tracking on all welding stations — compensates for incoming part joint position variation
- PLC master control coordinates all 15 robots and inter-station material flow as a single integrated system
- AGR-manufactured positioners custom-configured for crane bracket geometry and load requirements
- Offline programming for all product variants — no robot downtime during program changeover
- Pre-commissioning validation on equivalent components in AGR's own facility — reducing on-site startup time
15-robot coordinated line. PLC master control. Single integrated system across all stations.
Fully automated excavator boom
welding line with zero manual intervention.
Designed and integrated by AGR for its own group's structural fabrication facility, this line produces excavator booms as a Tier 1 supplier to a global top-tier construction machinery OEM. The system is in daily production and open to buyer visits.
AGR's group structural fabrication facility required a fully automated welding solution for excavator boom production — supplying components directly to one of the world's largest construction machinery manufacturers.
The production requirement was complete automation from incoming component to finished weld — eliminating operator dependency, reducing cycle time variation, and enabling multi-model production without manual program selection or fixture adjustment.
- Multiple excavator boom variants — different models, dimensions, and weld programs on the same line
- Zero manual intervention requirement — full material flow automation from load to unload
- Incoming part variation — upstream cut-to-length tolerance requires automatic joint position compensation
- OEM supplier quality standard — weld quality and dimensional output held to global top-tier OEM acceptance criteria
- Cycle time target — automated throughput must match or exceed manual production rate
- QR code on each incoming component — camera identifies workpiece type, dimensions, and variant on arrival
- Handling robot loads component onto positioner automatically — no operator loading required
- Hydraulic clamping fixture locks automatically on load — consistent positioning for every cycle
- Correct weld program called automatically from QR identification — no manual program selection
- 2 dedicated welding stations — optimised for boom geometry and thick-section multi-pass requirements
- Post-weld: handling robot transfers finished component to AGV automatically for downstream flow
- Full material flow automation — load to unload with zero manual intervention
- Multi-variant production without changeover downtime — QR-driven automatic program selection
- Consistent weld quality meeting global OEM supplier acceptance criteria — maintained in ongoing production
- System currently in daily production operation
- Available for qualified buyer site visits — no pre-arranged demonstration, live production observation
Complete automated flow. QR identification to AGV unload.
Handling robot + QR identification. Automatic program selection on each cycle.
Hydraulic automatic clamping. Consistent positioning every cycle, every variant.
Stator and rotor welding system
for wind turbine OEM supply chain.
All robotic welding systems in a structural fabrication facility supplying three of the world's top wind turbine manufacturers — including the global number one — were designed and integrated by AGR. 100% UT inspection, third-party verification, zero tolerance for weld deviation.
AGR's group structural fabrication facility supplies wind turbine structural components to three of the world's largest wind turbine OEMs — collectively representing the majority of global installed wind capacity.
The welding requirements for these components represent the most demanding inspection standard AGR has worked to. Every robot on this production floor is an AGR-integrated system.
- 100% UT inspection — every component, every weld, no sample-based acceptance
- Third-party certified inspection personnel permanently on-site
- ±0.08mm dimensional tolerance on large-diameter components — thermal distortion must be controlled throughout multi-pass process
- Weld formation requirements — bead geometry and surface consistency specified to tolerance alongside structural integrity
- Single-side welding, double-side formation — no back gouging permitted on production components
- Multi-specification: 4X through 10X turbine series on the same system
- CLOOS QRH-405 robot on 3-axis gantry — full coverage of large-diameter circumferential seams without repositioning
- Dual-axis L-type positioner, 5-ton rated, ±0.1mm repeatability — dynamic component positioning throughout weld sequence
- Pulse MIG process with copper backing plate — full penetration, single-side weld, double-side formation, no gouging
- TOFD flaw detection integrated — real-time weld integrity monitoring throughout production
- Heat input controlled throughout sequence — distortion prediction applied at design stage, not corrected post-weld
- Quick-lock clamping with HMI — fast specification changeover across 4X–10X series
Gantry robot system. Dual-axis positioner. CLOOS arc control. TOFD inspection integrated.
Burner housing welding systems
for North America deployment.
3 robotic welding systems ordered by one of the world's leading combustion and environmental systems manufacturers, headquartered in Oklahoma, USA — following successful long-term operation of AGR systems at their China facility.
A global leader in combustion equipment manufacturing had operated AGR-integrated robotic welding systems at their China facility for an extended period. Based on demonstrated performance and service reliability, the client expanded to North America manufacturing with 3 additional AGR systems.
This represents AGR's first direct North America installation — a reference point for the service model, parts supply, and technical support capability required for overseas deployments.
- Multi-diameter burner housing range — single system must handle multiple shell specifications without extended changeover
- Thick-wall cylindrical joints — consistent circumferential weld penetration and formation across all diameters
- North America deployment — on-site installation, remote support, and parts supply logistics all required
- ISO and ASME compliance environment — client operates certified manufacturing facilities
- Performance continuity — client expected same output consistency as China facility
- Rotary positioner with defined safe loading zone — continuous production cycle without interruption for loading
- Pulse-controlled welding source — stable arc, low spatter, consistent bead across all specified shell diameters
- Rapid program switching — full diameter range handled without robot downtime between specifications
- Light curtain perimeter protection — full process automation with operator safety compliance
- AGR-manufactured hydraulic clamping fixtures — designed for cylindrical component geometry and size range
- Service model: on-site installation team + remote technical support + globally warranted components (FANUC, Lincoln, Binzel)
- 3 systems ordered for North America manufacturing facilities
- Client decision based on verified China facility performance — not proposal alone
- Systems delivered, installation phase in progress
- Establishes AGR North America service reference — on-site installation, remote support, parts from Canada node
- First direct AGR installation in the North American market
Burner housing circumferential welding. Rotary positioner, pulse MIG, multi-diameter program switching.
On-site installation and commissioning. AGR engineers present for full system startup and handover.
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