Yaskawa Southern Africa is working with Aerosud Aviation, a leading aerospace manufacturer and an internationally recognised supplier of aircraft interior systems, to implement a cutting-edge robotic TIG welding solution tailored to the exacting demands of aerospace production. The collaboration, demonstrating the two companies’ commitment to innovation, precision, and efficiency, will strengthen Aerosud’s production capabilities and ensure compliance with stringent original equipment manufacturer (OEM) standards.
The newly developed robotic welding solution speeds up production of components for the aerospace industry.
The project is led by Yaskawa National Project Manager Devon Prinsloo and Aerosud Welding Engineer Nico du Toit and demonstrates the potential of automation and robotics to transform aerospace manufacturing.
Nico du Toit explains that Aerosud needed to scale up the production of aluminium track cans for Airbus A320 aircraft and this was a key driver for the project. “Airbus is ramping up production on its Single Aisle aircraft, requiring us, as a single-source supplier, to increase throughput,” says du Toit. “This welding robot solution enables us to produce uniform welds repeatedly on 1.4 mm to 1.6 mm aluminium and to meet OEM specifications with the highest efficiency.”
The TIG welding process[1], chosen for its quality and precision, delivers clean, consistent welds with minimal distortion, essential for aerospace components. The solution integrates Yaskawa’s high-precision robotic arms, Fronius TIG welding systems, and a Servo-Robot Micro-Trac camera system, to ensure accurate seam tracking and filler wire positioning.
Devon Prinsloo highlights that, “The camera scans the weld seam before welding, enabling precise alignment. This ensures repeatability and reduces waste by minimising errors.
“Automation in TIG welding enhances safety, precision, and efficiency, all critical factors in aerospace manufacturing,” he adds.
Yaskawa’s expertise in robotics and software was instrumental in overcoming the complexities of aerospace welding. Using MotoSim simulation software, the welding process was planned in detail, to reduce potential programming errors and setup time. Additionally, the customised solutions developed by Yaskawa addressed challenges such as variable component geometries and maintaining consistency across diverse materials.
The impact on Aerosud’s operations has been significant. “The new technology improves workflow efficiency by reducing the need for rework and increasing yield,” notes du Toit. “Automation allows us to maintain consistent quality and scale up production at the same time. This positions Aerosud as a competitive, innovative supplier in the global aerospace market.”
The project illustrates Yaskawa’s commitment to its mission to push the boundaries of automation technology. “This collaboration reflects our dedication to developing solutions that address the most complex manufacturing demands,” says Prinsloo. “Aerospace manufacturing requires precision and reliability, and Yaskawa is proud to contribute to Aerosud’s growth and innovation.”
Looking ahead, the partnership between Yaskawa and Aerosud is set to explore new advances, including adaptive welding technologies. By leveraging their combined expertise, the two companies are paving the way for further innovation in aerospace robotics and manufacturing.
[1] TIG stands for tungsten inert gas and TIG welding is technically described as gas tungsten arc welding (GTAW). The process uses a non-consumable tungsten electrode that delivers the current to the welding arc. An inert gas, typically argon, protects and cools the tungsten and weld puddle.
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