Yaskawa Motoman Case Study

ACS-110.jpgCrane Outriggers (Construction Equipment), Arc Welding


  • Provide flexible robotic system capable of welding 26 different outrigger beam models distributed across three part families. Mild steel parts range from approximately 1,524-3,658 mm L, 6-19 mm thick and weigh 227-771 kg. Each beam requires 7-10 welds, ranging from approximately 51-3,048 mm L.
  • Achieve 27-minute cycle time for all models (one part every 0.45 hours). Depending on model, beams take 3-4 hours to weld manually.
  • Increase throughput and productivity to enable out-sourced beams to be brought back in-house.
  • Improve weld quality and consistency.
  • Allow skilled manual welders to be redeployed to other jobs within the plant.


Yaskawa Motoman provided a flexible triple welding system, including:

  • (3) 20-kg payload robots with individual controllers and base risers.
  • (3) Fronius TimeTwin TPS 5000 digital weld packages.
  • (3) Fronius Robacta Twin Compact 900-Amp water-cooled tandem-arc GMAW torch packages.
  • (3) Nozzle cleaning stations for tandem-arc torches. Reamer-type with wire cutter and anti-spatter spray.
  • (6) ComArc (200-V) seam-tracking and touch-sensing packages.
  • (2) Motoman® headstock/tailstock positioners with 3,000 kg rated load. MotoMount™ fixture mounting system included.
  • Common equipment base for controllers with table for welding power supplies.
  • Fixture package — adjustable spanner and hydraulic fixtures that accommodate required range of part lengths and models.
  • Operator station.
  • Cell guarding package that complies with ANSI/RIA R15.06-1999 standard, including 2.4-m woven-wire perimeter safety fence; arc flash protection curtains; (4) sliding gates with positive-break safety switches at positioner load/unload station for part flow-through; and three-color status beacon.


Yaskawa Motoman provided hydraulic clamping fixtures for the two headstock/tailstock positioners. A large spanner between the HS/TS faceplates is adjustable to accommodate various beam lengths. Two alignment clamps and two swing arms per fixture hold each part for welding. Fixtures include part-present and clamp open/closed sensors.

Project Results

  • Motoman system welds parts significantly faster than the 27-minute cycle time requirement. Some parts are welded in 13 minutes. Most parts average 17-18 minutes.
  • Customer was able to bring all out-sourced production back in-house, saving time and money.
  • Flexible robotic solution meets or exceeds project goals and objectives, and can weld all required parts.
  • Robotic tandem-arc GMAW system consistently produces high-quality heavy-deposition welds and enables skilled manual welders to be redeployed elsewhere in the plant.

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