Welding is one of the main uses of industrial robots. Whereas spot welds and single passes have long been established in standard work environments, robot have had limited use in multipass welding of large steel structures because of the high risk of welding errors that go undetected during the process and the complex safety precautions. Large weldments have to be amply blocked off to ensure safe robot operation. This results in long setup times and prevents humans and machines from being able to work on the same part at the same time.

New technologies for better safety and quality

This is why two key technological approaches are being pursued in the SIMMI project. Intelligent process monitoring using a novel sensor and control system will ensure that relevant welding parameters are monitored continuously, checked against setpoints and corrected automatically. This will make welding errors preventable, which were previously only detectable afterward and required considerable work to correct. The project partners are additionally researching mobile safeguard systems for robot work zones. Rather than entire buildings or complete weldments, only a robot’s actual work zone will have to be blocked off in the future. This will increase the flexibility of robot use, shorten setup times and enable safe simultaneous work by workers and machines.

Occupational Health and skilled labor retention

In addition to the improvement of quality and efficiency, occupational health is also playing a key role. Welding of large parts produces substantial quantities of harmful gases and fumes that make the workplace hazardous and necessitate safety precautions. Continuous control and optimization of the welding process will cut gas and fume emissions. The project is consequently contributing to manufacturing safety and additionally improving employees’ work conditions. At the same time, increased robot use will boost the attractiveness of the welding profession since it will reduce hazardous work.

The project partners

ATA Anlagentechnik Aschersleben GmbH specializes in the manufacture of steel weldments weighing up to 160 tons. The custom equipment manufacturing and systems engineering company provides a wide range of products and services, from steel structures to machine tool building up through machining and surface finishing.

Polarith GmbH in Magdeburg develops and sells information and communications technology systems particularly focused on automated application and sensor data analysis and processing. In addition to its own products such as the automated Cranium system, the company also provides software development and industrial automation services.

Fraunhofer Institute for Factory Operation and Automation IFF in Magdeburg has years of experience in robotic systems, safe human-robot interaction, sensor systems and 3D image processing. The institute regularly works on national and international research projects and has established itself as a partner for the development of universal robot applications for industry and manufacturing.

The SIMMI project started on January 1, 2025 and will run until June 30, 2027. It is being funded by the European Union and the state of Saxony-Anhalt.