As FABALP Makine, we have successfully completed two spot welding fixture projects specifically developed for the automotive industry. Both the design and manufacturing processes were carried out in-house, and commissioning and testing were completed by our technical team on-site.
The project was planned to meet performance criteria such as high repeatability, ergonomic use, and fast cycle times. All welding points and robot access areas were 100% verified through digital simulation with Process Simulate.
🔧 Project Summary
The two different spot welding fixtures developed in this project are designed to fix two separate sheet metal components in a robotic spot welding cell.
🛠️ Technical Details:
- Fixture Type: Pneumatic clamp spot welding fixture
- Part Type: Sheet metal body components
- Robot Brand: ABB
- Simulation: Siemens Process Simulate for reachability and collision control
- Clamping System: Tuenkers clamps operating at 5 bar
- Material: ST52 steel construction + machined top plate areas
- Positioning Accuracy: ±0.1 mm
🖼️ Images from the Project
📐 Simulation and Design Process
Simulation studies started using 3D part models provided by the customer.
- Robot reachability to all weld points verified via Process Simulate
- Jaw movement scenarios tested digitally
- Operator access, cycle time, ergonomics, and safety analyzed
- Engineering validation performed considering clamp sequence and weld tolerances
🏭 Manufacturing and Commissioning
The manufacturing process of the fixtures included the following steps::
- Welded Assembly: ST52 steel body
- Machining: CNC machining of top plate, reference pin sockets, and fixture slots
- Painting and Labeling: Electrostatic powder coating and safety labels
- Assembly: Installation of pneumatic systems, sensors, and reference pins
- Testing: Clamp/unclamp trials, idle cycle tests
- Commissioning: On-site installation and operator training
🎯 Why Spot Welding Fixtures?
Spot welding fixtures are critical in sheet metal production for precise positioning and improved weld quality.
✅ Minimizes operator error
✅ Reduces cycle time
✅ Enhances weld quality and symmetry
✅ Ensures robot access
✅ Enables production standardization
🌍 Applications
This type of spot welding fixtures is widely used in the following industries and applications:
- 🚗 Automotive body assembly lines
- 🚌 Rail vehicle chassis manufacturing
- 🏗️ Industrial equipment cabinet production
- 🔩 Metal case and profile systems
🏁 Conclusion
At FABALP Makine, we optimize your production processes with custom welding fixture solutions. From design to field support, we provide end-to-end services entirely in-house.
📞 Contact Us
Let’s partner in your upcoming projects. Contact us for custom fixture designs, robot bases, and automation solutions.