Aluminum Spot Welding Automation for Automotive Parts using KUKA KR120

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Aluminum Spot Welding Automation for Automotive Parts using KUKA KR120

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Application Field: Industry > Automotive, Application > Welding, Sector > Manufacturing

Industry > AutomotiveApplication > WeldingSector > Manufacturing

#SpotWelding#AluminumWelding#AutomotiveParts#KUKARobot#KR120#WeldingAutomation#ServoGun#QualityConsistency

Process Overview

This welding automation solution uses the KUKA KR120 to perform aluminum spot welding for automotive parts, enabling faster welding operations and multi-angle access through a welding robot system.

By applying a high-precision, high-speed industrial robot, the solution supports accurate and stable welding even on complex-shaped parts, securing high productivity and consistent welding quality.

Components

Robot	KUKA Ready2_spot KR120 R2700 6-axis articulated robot Payload: 120 kg Repeatability: ±0.05 mm Working range: 2,701 mm Total weight: 1,069 kg KUKA.ServoGun Software Spot package Welding controller: KR C4 KUKA automatic teaching playback function with sensor-based compensation Process switch cabinet Robot controller
Peripherals	Robot mounting base Workpiece fixing and rotating jig (separate configuration)

Workflow

STEP 1.	Workpiece loading
STEP 2.	Rotate the workpiece fixing jig
STEP 3.	Spot welding operation aligned to welding positions
STEP 4.	Rotate the workpiece fixing jig to the discharge position

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Features

Excellent Welding Quality and High Process Flexibility

Ensures fast welding operation and stable quality by applying a high-precision, high-speed industrial robot
Enables multi-angle welding access on complex curved workpieces using a 6-axis articulated robot
Supports stable aluminum welding performance

Stable Installation and Operation with a Dedicated Spot Welding Package

Ensures stable installation and operation by applying a dedicated welding package
Reduces installation time and commissioning lead time through a dedicated spot package configuration
Protects against electrostatic discharge and electrical noise through ESD prevention functions
Ensures stable welding performance

Results

Key Benefits	Increased productivity Secured consistent welding quality
Client Feedback	Installation and trial operation were completed quickly, and we were satisfied to achieve stable aluminum welding quality.

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