Automatic welding system developer SmartTCP (www.smarttcp.com) was selected by Waiward Steel Fabricators Ltd. to automate it structural steel welding process. The robotic welding solution — designed for steel fabrication — combines hardware and software into a flexible and efficient welding cell that will automate robot programming and weld production.

While researching automated welding options Waiward Steel was specific in its requirements when talking with robotic solution suppliers. They needed a complete solution to deal with high-piece count projects with “batches of one.” The solution would have to deal with the specialized welding demands of structural steel including large multi-pass welds on thick beveled material, full penetration, heat distribution, and the ability to handle inaccuracy/variances in part fitting and joint gaps.

“When we saw the SmartTCP solution we knew that this was the solution,” said v.p. of operations, Jim Kanerva. “It was as if it was designed specifically for our situation and for our industry.”

The SmartTCP solution to be implemented in the Waiward facility will include a bridge gantry system 125-ft long with two SmartTCP head-and-tail positioners (30,000 lbs. capacity each) specifically designed for structural steel, one ceiling mounted, six-axis articulated robot, welding equipment, and the SmartTCP welding automation software. The system will allow the fabricators to produce more parts more quickly, without additional employees and in the same amount of production space.