Solutions / Integrated Lines
Solutions — 02

Integrated
Welding
Lines.

Multi-station production systems where welding is one step in a coordinated material flow. PLC coordination, handling logic, and station sequencing engineered as a system — not assembled as connected islands.

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AGR integrated robotic welding line — multiple stations, full production line view Integrated Line — Multiple robots, full production line view, station coordination, industrial scale
Line Architecture

Welding Is One Station
in a Larger System.

An integrated line is not a collection of welding cells joined by conveyors. It is a production system where loading, positioning, welding, inspection, and unloading are engineered together from the start.

Architecture 01
Station Sequencing
Each station's cycle time, buffer logic, and transition sequencing is designed as part of the line — not configured after installation. Bottlenecks are identified and resolved at the engineering stage.
Architecture 02
PLC Coordination
Siemens or Mitsubishi PLC logic controls station communication, interlock conditions, and fault recovery. Not a robot controller managing everything — a dedicated control architecture designed for production reliability.
Architecture 03
Handling Integration
Roller conveyors, transfer carts, gantry systems, or AGVs — selected and integrated based on part weight, geometry, and cycle time requirement. Handling is part of the engineering, not an add-on.
What Integrated Lines Solve

System-Level Problems Require
System-Level Solutions.

Problem 01
Multi-Variant Production
Multiple part types passing through the same production system. Fixture changeover, program switching, and seam tracking adaptation must all be engineered for the actual variant range — not optimised for one part type.
Problem 02
Throughput at Scale
High production volume where station cycle times, buffer sizing, and shift-length stability directly affect output. A system that performs on first-off qualification but drifts over shift length is not fit for purpose.
Problem 03
Quality Over Volume
Inspection-sensitive applications where every weld across the full production run must meet the same acceptance criteria — not just the qualification sample. Process consistency is a system design requirement.
Scope of Delivery

What an Integrated Line
Typically Includes.

Welding Stations
Multiple robotic welding stations, each with robot, positioner, fixture, and process engineering matched to the specific weld at that station. Stations are not identical — each is configured for its role in the sequence.
PLC System
Siemens S7 or Mitsubishi iQ-R PLC controlling line sequencing, station interlocks, fault detection, and recovery logic. HMI panels at key stations for operator visibility and intervention.
Material Handling
Conveyors, transfer systems, or gantry loading — selected for part weight and geometry. Automatic transfer between stations or operator-assisted depending on application and budget.
Fixture System
Station-specific fixtures with quick-change capability for multi-variant production. Hydraulic clamping where cycle time requires it. Fixture changeover logic integrated into PLC sequencing.
Data & MES
Production data logging (cycle time, fault history, weld parameter records) available as standard. MES integration (SAP, proprietary systems) available on request — interface specification required at project start.
Commissioning
Full line commissioning including station-by-station process validation, line sequencing verification, and throughput qualification. First-run inspection validation before handover.
Selection Guide

Is an Integrated Line
the Right Choice?

An integrated line is appropriate when:
  • Production volume justifies multi-station automation
  • Multiple weld operations on the same part require sequential stations
  • Handling between operations is a current production bottleneck
  • MES integration or production data is a requirement
  • Multi-variant production requires coordinated changeover management
Consider a different approach when:
  • Production volume does not justify multi-station investment — consider welding cell
  • Challenge is a single weld operation — consider welding cell
  • Fixture and positioning are the primary constraint — consider tooling first
  • Production is highly variable with frequent part type changes
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Welding Cells
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Tooling & Positioners
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Discuss Your Application

System Scope Follows
Production Reality.

The right line configuration depends on part family, volume, variant count, and inspection requirements. The assessment begins from your specific production constraint — not from a catalogue.

Request Technical Assessment

Useful to share in your enquiry:

  • Number of weld operations and sequence
  • Part family — types, weights, dimensions
  • Target throughput (parts per shift)
  • Current production bottleneck
  • MES or data integration requirements