I. Project Background
Corrugated plates are widely used in rail transit and containers, with plate thickness of only 0.8–2mm and irregular curved surfaces, making heat input control for pulse spot welding extremely strict. Jiudu Intelligent Technology (Shanghai) Co., Ltd. faces the pain points of easy burn-through on thin plates, poor weld-spot consistency, heavy programming workload with traditional teaching robots, and a scarcity of skilled welders for high-difficulty spot welding, urgently needing an automated spot welding solution.
The company chose 3Srobotics for its equipment with 3D vision that adapts to corrugated curved surfaces without point-by-point teaching; an S-series welder process-optimized for thin-plate pulse spot welding with precise heat input control; a large 8-axis cantilever working range supporting dual-machine parallel operation; and a local same-region layout enabling efficient and timely process debugging and after-sales response.
II. Solution & Implementation
3Srobotics deployed multiple 8-axis cantilever intelligent welding systems with S-series intelligent welder systems for corrugated plate pulse spot welding. The equipment relies on 3D vision to scan corrugated plate surfaces in real time, automatically recognizing the 3D positions of weld spots and dynamically adjusting torch posture and height to adapt to surface changes without advance programming. The welder system precisely regulates pulse current, pulse duration and cooling time to keep heat input within the process window, balancing weld-spot nugget strength while avoiding thin-plate burn-through defects. Two systems operate in parallel across different zones, sharing welding tasks and improving overall output. The system fully retains process parameters such as current, voltage and pulse time for every weld spot, making spot quality data traceable. Operators only need to handle loading/unloading and startup confirmation.
III. Project Value & Results
The project realized automation of the corrugated plate pulse spot welding process. Two systems work in coordination, replacing 1.5–2 skilled welders and easing the shortage of highly skilled welders. Through precise heat input control, thin-plate burn-through and poor-fusion problems are effectively improved, and the welding pass rate rises significantly. The nugget size and formation state of each weld spot are highly uniform, guaranteeing overall component strength and sealing. All welding process parameters are automatically recorded and retained, providing data support for process iteration and quality control, and achieving stable, large-scale production of spot welding on complex thin-plate curved surfaces.
