In today’s automative and engineering industries, nothing is more valuable than the ability to respond quickly and efficiently to production changes. Automotive Painting Partners (APP), a specialist in metal surface treatment, is introducing a new solution that significantly expands production capabilities in the field of robotic welding. The new flexible workstation will be operational by the end of the year, enabling customers to handle pre-series production, small batches, and capacity peaks with maximum efficiency.
Small-series production, speed, flexibility, and cost efficiency
These are the main advantages of the new flexible workstation. Thanks to its high versatility and rapid fixture exchange, technicians can prepare the line for a new product within hours, whereas on a traditional large robotic line, fixture replacement, reconfiguration, and reprogramming can take several days. This makes small-batch production economically viable – particularly in cases where the customer does not want (or cannot afford) to invest in running a large-scale line.
Cutting-edge robotic welding technologies
At APP, we offer comprehensive services and tailor-made solutions in robotic welding – from single operations to complete welding of structural body assemblies. We cover the entire process, from concept design, fixture construction, and automation, through process optimisation, to production launch. Our experience with welding parts ranging from 20 cm up to approximately 1.5 m already demonstrates our high technological standards today. The new workstation builds on this expertise, taking capabilities even further – towards faster and more cost-effective solutions.
Two different products in a single day
At the core of the new workstation are two welding cells with four robots, which can be further expanded depending on project needs. A major advantage is that each cell can work on a different product – for example, one can produce complete bumper assemblies while the other prepares their subassemblies. This allows customers to receive two different products at the same time.
A key element is the horizontally rotating programmable positioners, which hold the welded parts. Fixtures can be exchanged very quickly – not only physically but also at the software level – thanks to the fast switching of robotic programs and welding parameters. The result is maximum flexibility without compromising quality.
The most advanced equipment in the industry
The flexible welding cells will be equipped with the same cutting-edge technology that we use on our main production line in Police nad Metují, Eastern Bohemia:
- Fronius CMT welding process – an almost spatter-free method with low heat input, enabling the welding of demanding materials such as galvanized sheets or thin, hard-to-join metals. Offers up to twice the speed compared to conventional methods.
- Latest-generation Kawasaki welding robots for MIG/MAG applications, combined with handling robots from the same manufacturer. Controlled by Siemens systems, using top-class Fronius welding units, with TIG technology available for specific applications.
Ready to meet the demands of diverse production environments
At APP, we know the new workstation will find immediate use – not only as reliable support during production peaks and a backup to our main line, but also as an independent unit for customized small-series manufacturing. The robotic and welding technologies we deploy are state-of-the-art, with remote access for management and service available directly from the Czech Republic, Germany, and Poland. With this new solution, our welding capacity will expand significantly while also creating free capacity for new customers.
Do you need to quickly and reliably weld a smaller series of parts? Looking for a flexible solution for pre-series production or capacity fluctuations? Get in touch – we’ll help you accelerate development and make your production more efficient.
