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Heavy Structural Steel and Thick Plate Welding Cell for Custom Industrial Automation
We provide specialized custom industrial welding solutions through human-robot collaboration and robotic cells for large-scale excavator manufacturing and shipbuilding. LPR Global provides specialized welding cells for large-scale excavator manufacturing and shipbuilding. These systems are built to manage the immense weight and heat management requirements of thick-plate welding.
Our welding cells consist with articulating robot arms, robot carriages and positioners.
- Extended Reach & Mobility: By pairing robots with carriages, our systems easily traverse the long spans of large-scale structures.
- Optimal Torch Positioning: Advanced positioners rotate and tilt workpieces to ensure the robot maintains the ideal welding angle at all times.
- Advanced Seam Tracking: Our high-precision weld seam tracking system automatically adjusts the torch head in real-time, preventing thermal warping and ensuring consistent, high-quality weld beads.
High-Capacity Applications:
- Ship Engine Blocks: Custom cells featuring 4 robots and 4 carriages designed to handle 20-ton workpieces.
- Construction Machinery: Proven operation for excavator lower center frames, upper drums, and front axles.
Our thick welding plate cells are in operation for manufacturing engine blocks, excavator lower center frame upper drums, and excavator front axles. Our clientele includes Doosan Infracore and Dongyang Group.
Ship Engine Block Assembly Welding Cell
Most recent projects include robotic assembly welding cells for ship engine blocks, which weigh 20 tons while the plate thickness is 50 – 100mm. The welding cell has 4 robots, 4 robot carriages and 2 positioners.
Custom Industrial Automatic Precision Welding Machines and Welding Fixtures for Smart Factories
LPR Global delivers custom industrial robotic welding solutions for many applications in automotive sub-assemblies, assembly lines, EV battery assembly line, shipbuilding, and heavy machinery industry. Our systems are designed to minimize robot travel time, eliminate single-point failures, and provide cost-effective custom layout without compromising cycle time or weld quality.
After providing a wide range of clients with automated welding cells and welding assembly lines, we understand the importance of custom industrial design ability of fixtures and tooling. We then fully utilize fixtures and tooling when we create layout of automated welding line with robot arms. Fixtures such as rotating positioners are excellent time and money saver for automotive parts, predictable and repeatable orientations because robot arms would take too much travel time between welds, defeating the purpose of fully automated welding cells or lines.
Automotive & EV Battery Assembly
Our custom industrial automated welding systems for complex cradle geometry of automotive engines have a combination of robot arms and turntables. While the layout minimizes robot arm torch wrist contortion, each turntable indexing handles flips and rotations of workpieces to be welded. This robotic welding system guarantees 44 second cycle time per ef-car front engine cradle.
Fixturing Accuracy and Repeatability
Inconsistent weld quality is a common challenge in custom industrial automation, often caused by inaccurate workpiece positioning rather than the welding process itself. To eliminate this, we utilize dedicated, hardened locator tooling tailored to each sub-assemble-to-be or assemblies. For clients integrating manual processes with automated lines due to space or budget constraints, we also offer quick-change fixture plates on each pallet. These allow operators to pre-load and inspect parts offline, ensuring total accuracy before the pallet enters the cell., we offer quick-change fixture plates.
Under-Shuttle and Over-Shuttle for Minimum Robot Idle Time
When your cycle time is demanding, you don’t want robots to stop and wait until loading and unloading process gets completed. We mix under-shuttle and over-shuttle system for flexible part feed and removal. Depending on throughput rate and buffering, we combine under-shuttle and over-shuttle. A combination of shuttles provides buffer capacity to keep weld cells fed during loading bursts or temporary blockages.
Preventing Downtime
When we calculate cycle time and layouts, we always ensure that single-point failures don’t stop the entire line. Calculating optimal spare capacity and layout design to reduce full-line downtime is our specialty. Bottom of Form
We also supply our custom industrial spot-welding systems to Hyundai, GM, KIA, LG, and YASKAWA. Below is our automated spot-welding lines for EV Battery pack application.
Please visit this page for more application of Spot/Arc welding in the automotive industry.
Custom Industrial Pick and Place Automation: Metal Sheet Stacking, Inserting, Feeding, and Conveying
LPR Global combines robotic programming and mechanical structure manufacturing with over 15 years of custom industrial automation design expertise. Having completed more than 350 automation projects, we provide robust handling and feeding solutions tailored to the unique demands of the steel, automotive and hydraulic press manufacturing.
We customize gripping methods and smart transferring methods based on application. Grippers that we offer include mechanical, magnetic and vacuum grippers. Transferring systems that we offer include conveyors, rack and roller pinions, and gantry systems. All mechanical components are manufactured by specialty shops in South Korea while robot programming and integration is conducted by robotic line designers, specialized in clients’ applications and industries.
Key Applications
- Press Loading and Unloading
- Forging Press Feeding for Steel Melting Line
- Blanking Plate Handling
- Stacking System for High-Speed Presses
Servo-Driven Air-Float Stacking Systems
High-Speed, Zero-Defect Piling for Blanking & CTL Lines
LPR Global’s stacking solutions are in operation at POSCO and other leading steel service centers for the most demanding automotive and steel blanking lines. By combining synchronized servo-motor control with pneumatic air-float technology, we provide a frictionless transition from shear to stack, ensuring that clients’ “Class A” surfaces remain pristine even at maximum production speeds.
Our system eliminates edge peening or surface scratches through a controlled “air cushion” descent.
- Zero Surface & Edge Damage: The air-float mechanism creates a high-volume, low-pressure cushion that suspends the blank, allowing for a soft, frictionless landing.
- Total Shape Flexibility: Unlike mechanical grippers, our air-float and servo-positioning system is free from shape constraints, allowing you to handle rectangular, trapezoidal, and complex contoured blanks.
- Positioning Accuracy: Achieve perfectly squared stacks with a positioning tolerance of +/-0.3mm.
Performance Specifications
Our piler is designed to keep pace with high-output blanking presses and Cut-to-Length (CTL) lines, offering a significant boost in strokes per minute (SPM) without sacrificing part quality.
| Feature | Specification |
| Blank Length Range | 250 mm – 2,000 mm |
| Blank Width Range | 300 mm – 1,850 mm |
| Piling Speed (Standard) | 25 SPM |
| Max Peak Speed | 30 SPM |
| Positioning Accuracy | ±0.3 mm |
| Material Compatibility | Steel, Aluminum, Stainless, and Pre-painted |
Custom Industrial Automatic Piler
Automotive and Battery Industry
Our commitment to tight tolerances and high accuracy has established us as a trusted partner for industry leaders such as KIA, Hyundai, LG, and Atlas BX.
The handling of automotive and battery components often involves managing semi-finished parts that are highly susceptible to damage. To ensure zero deformation and maintain the structural integrity of these delicate items, we leverage our deep engineering expertise to design customized vacuum-based end-effectors.
By combining sophisticated sensors with specialized vacuum technology, we deliver custom industrial handling solutions that provide a secure grip without compromising the surface finish or geometry of the component.
