The FlexCell incorporates servo-gun technology with positioning robots to create a flexible welding cell. A leading manufacturer of seat frame assemblies for the automotive industry needed a new system to attach seat cushions to the seat frame using resistance welded joints. They needed a system that used advanced spot welding to produce a single unit at a time with minimal disruption between units. The system also had to be flexible enough to accommodate future products without costly retooling.

Putting the SuperCell concept to work, Automation IG produced a single weld cell for both resistance and arc welding. By automating the unloading process, Automation IG increased the production of the entire floor by freeing the operators to focus their attention elsewhere. Drawing on decades of welding experience, Automation IG’s engineers and technicians used servo-gun technology to enhance the cell’s resistance welding capabilities.

The servo-gun’s extra control and automatic tip calibration eliminates problems that arise in pneumatic resistance welding such as tips that wear and cause various points of contact. During the manufacturing process, Automation IG’s control system automatically performs all calibrations and modifies robot points. When the customer needed to accommodate a new project, Automation IG designed additional tooling that can run on the same cell. By using Automation IG’s FlexCell, our customers can:

• Maximize floor space
• Produce single, custom units just in time.
• Change products instantly and automatically.
• Reduce labor.
• Improve the quality of resistance welding.