As the manufacturing industry continues to upgrade toward automation and flexible production, more and more automotive and motorcycle parts manufacturers are placing greater emphasis on welding stability and production efficiency.
Recently, a complete 8-axis coordinated robot laser welding workstation provided by PDKJ was successfully installed, commissioned, and officially delivered for production use at the customer’s factory.
This project is mainly used for welding1.2mm stainless steel motorcycle crash bars. Through an automated robotic welding solution, the customer has achieved stable, efficient, and large-scale production.
Ⅰ Project Background
Customer Overview
The customer is a manufacturing enterprise specializing in automotive and motorcycle safety components, focusing on the R&D and production of:
Vehicle structural parts
Protective components
Their products are widely used in various passenger vehicles and motorcycles, with strict industry standards for:
Welding strength
Appearance consistency
Production stability
Project Motivation
As order volumes increased, the customer placed higher demands on:
Welding quality
Appearance consistency
Production cycle efficiency
However, traditional manual welding methods gradually exposed several practical production issues during long-term operation.
Ⅱ Customer Production Pain Points & Core Requirements
The welded product in this project is a stainless steel motorcycle crash bar.
The product features:
Thin-wall tubular structures
Multiple welding angles
Complex welding paths
This creates high requirements for welding precision and stability.
During long-term production, the customer encountered several major challenges:
1. Thin Stainless Steel Was Prone to Deformation
The 1.2mm stainless steel material is relatively thin.
Traditional welding methods generate excessive heat input, leading to:
Burn-through
Blackened weld seams
Workpiece deformation
Increased post-weld grinding workload
For appearance-critical parts, welding consistency is especially important.
2. Manual Welding Stability Relied Heavily on Operator Experience
The motorcycle crash bars involve complex curved surfaces and changing welding angles.
During manual welding:
Weld seam consistency was difficult to maintain
Long production runs caused operational deviations
Training new workers required significant time
Especially under mass-production conditions, stable production became a major concern for the customer.
Customer Requirements
The customer aimed to:
Increase production capacity
Reduce dependence on manual labor
Improve welding pass rates
Optimize overall production efficiency
Ⅲ Key Features of the PDKJ Solution
Based on the customer’s product structure and production needs, PDKJ configured the workstation with:
Yaskawa robotic arm
Laser welding system
8-axis coordinated control
Customized fixtures
Safety protection fencing
Automated control system
Together forming a complete robot laser welding workstation.
The solution focused on solving:
Thin stainless steel deformation
Complex weld seam formation
Automated production challenges
1. 8-Axis Coordination Improves Flexibility for Complex Welding Paths
This project adopts an 8-axis coordinated motion system, making it especially suitable for irregular tubular workpieces such as crash bars.
During welding, the robot can achieve:
Multi-angle motion coordination
Automatic welding torch posture adjustment
More stable trajectory control
This significantly improves welding consistency for complex workpieces.
2. Laser Welding Process Precisely Matches 1.2mm Stainless Steel
The workstation uses laser welding technology optimized for:
Welding power
Welding speed
Defocus parameters
specifically for 1.2mm stainless steel.
Advantages include:
Low heat input
Effective control of deformation and oxidation
Attractive weld seam appearance
Significant reduction in post-weld grinding
This greatly improves product appearance quality.
3. Safety & Ease of Operation for Real Factory Environments
The workstation is equipped with:
Fully enclosed safety fencing
Safety light curtains
Emergency stop devices
to ensure safe production operation.
In addition:
The visual operation interface simplifies program editing and parameter adjustment
Operator skill requirements are reduced
Welding data recording and traceability are supported
helping the customer establish a standardized quality control system.
PDKJ also designed customized fixture solutions according to the customer’s product structure.
Benefits include:
More stable workpiece positioning
Higher repeat clamping accuracy
Better consistency for batch production
further ensuring stable welding quality.
Ⅳ Delivery Results | Stable Production Creates Value
The complete “Robot Arm + Laser Welding Machine” workstation has now completed installation and commissioning and has officially entered production operation.
According to on-site production feedback:
Equipment operation is stable
Weld seam formation is consistent
Product qualification rates meet production requirements
Automated production cycle times meet customer expectations
The customer expressed strong satisfaction with both the welding quality and overall equipment performance.
Take Action Now
Choose PDKJ and enjoy five key guarantees for worry-free cooperation:
Free Sample Testing – Try Before You Buy Test your parts first and proceed only when satisfied
Factory Direct Supply – Cost Savings No middlemen, direct factory pricing
Professional Technical Support – Full Guidance One-on-one engineering support for welding solutions
Full Machine Warranty – Reliable Service Original components with comprehensive warranty
Customized Solutions – Tailored to Your Needs Flexible solutions for various metal welding applications
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Professional Services by Guangdong Pudian Automation Technology Co., Ltd.
Guangdong Pudian Automation Technology Co., Ltd.
20 years of expertise in resistance welding, laser welding, and automated welding equipment
Focus on high precision, high stability, and customized solutions
Full coverage of processes including spot welding, projection welding, seam welding, rolling welding, laser welding, and automated production lines
One-on-one customized welding solutions based on material, thickness, and production volume
Serving multiple industries and solving complex welding challenges
Automated welding is not merely a substitute for manual labor; rather, it helps enterprises achieve production methods that are more stable, efficient, and sustainable.
If you currently have requirements for:
Stainless steel product welding
Thin-sheet welding
Pipe and fitting welding
Robotic automated welding
Customized, non-standard welding machinery
You can contact Guangdong Pudian Automation at any time:
On-site visits to understand your production needs and customize exclusive welding process solutions
Full-process follow-up to ensure equipment implementation matches your production rhythm
Founded in 2006, PDKJ is a professional supplier of welding automation solutions. The company has passed the ISO9001 international quality management system certification, has more than 90 officially authorized and applied national patents, and a number of core technologies in the welding field fill the technical gap at home and abroad. It is a national high-tech enterprise.
