ROBBI Mobile cobot

“ROBBI Mobile cobots overcome traditional barriers to welding automation, especially among small- to medium-sized businesses,” says Dan Colvin, ESAB Vice President, North America Robotics & Digital Solutions. “They deploy quickly and easily, feature operator-friendly controls, require no robotic programing knowledge and are suitable for high-mix/low-volume and medium- to high-volume production runs. ESAB automation solutions enable fabricators and manufacturers to leverage the talents of existing staff, strengthen profitability and improve the operator’s working environment.”

Welding Cobots

ROBBI Mobile welding cobots feature a Universal Robots’ UR10e or UR 20e industrial robot arm and a Siegmund 32- x 48-in. or 5- x 10-ft. table. The ESAB Teach Tool uses a ‘no code’ or plain language program so users can effortlessly incorporate a multitude of functions that enhance performance and productivity.

“ROBBI offers the most intuitive operation of any welding cobot on the market, enabling fabricators to start producing more parts almost immediately,” adds ESAB’s Colvin.

ROBBI is now available with the Aristo Edge 500R power source and RoboFeed Edge robotic wire feeder. Aristo Edge 500R ensures precise arc starts and enhanced stability across four advanced WeldModes — THIN, ROOT, ROOT Pipe and SPEED — as well as an Advanced Pulse WeldMode. All WeldModes enhance arc stability, offer more control at faster travel speeds and reduce spatter for less post-weld clean-up. The Aristo Edge platform also empowers independent development of synergic lines.

Rail and Wheel Option Tractors

Tracfinder Rail is designed for welding in all positions using high-stability rails and a rack-and-pinion transmission to prevent slippage at speeds up to 71 in./min (180 cm/min). Its unique joint-teaching software enables users to create a weld path with up to 50 points.

Tracfinder Wheel, the most versatile autonomous welding tractor on the market, features a magnetic base with 62 lbs. (28 kg) of magnetic force that enables it to operate in all welding positions at speeds up to 79 in./min (200 cm/min), including vertical up and down, overhead and on inside and outside diameters. New tracking software adjusts the Tracfinder Wheel’s trajectory based on torch position, eliminating the need for rails and minimizing setup time. Dual motorization (independent left/right control) and 4-wheel drive ensure optimal traction and stability in all welding positions. The optional remote control lets users adjust direction while the tractor is moving, much like a remote controlled car.

Designed for maximum flexibility, Tracfinder tractors feature a common operator interface that is available with Standard, Advanced and Advanced+ control packages. The two Advanced packages feature a remote control interface for operations up to 66 ft. (20 m) away, as well as advanced software. The Advanced+ package also features a communication module for two-way communication with the Aristo^® Edge 500R power source and RobustFeed Edge wire feeder; otherwise, Tracfinder works with any brand of welding power source.

The Tracfinder advanced controllers enable users to save up to 30 jobs, storing programs for tractor parameters that include weld speed and length, delays, repetitions, stitch welding, back-step welding, three standard weaving patterns, the ability to customize the weave dwell time, width and speed, and a special multi-axis weaving function that combines horizontal and vertical weaving. Because all systems feature a common central control base and components, users can start out with the Standard control and upgrade to an Advanced or Advanced+ control.

By making continuous welds, Tracfinder tractors reduce rework associated with start/stop defects. In applications where end-users expect uniform weld bead profile and penetration, mechanized tractors deliver consistency without the cost or complexity of automation. They also reduce operator stress by reducing fume and UV radiation exposure, as well as reduce welding in uncomfortable positions.

Applications include those associated with shipbuilding, offshore yards, structural steel, tank and vessel, pipeline, wind tower, repair and maintenance (especially hardfacing) and high-volume fabrication. Operating time for the carriage battery is between 10 to 20 hours, enabling the tractor to run for an entire shift before swapping out the battery, which is a standard Li-ion 18V power tool battery.

For conventional MIG and pulsed MIG processes, ROBBI pairs with the Aristo 500ix power source and RobustFeed U82 wire feeder, which feature pre-programmed synergic lines for common welding alloys.

Contact your ESAB representative or visit ESAB’s website to learn more about ESAB’s full portfolio of automated and mechanized solutions.

About ESAB

For more than 120 years, ESAB has been a world leader in fabrication technology. Our distinctive portfolio of fabrication solutions encompasses more than 40 of the world’s most trusted brands for welding and cutting equipment, automation, robotics, fabrication software, filler metals, gas flow control, and PPE. Industries and innovators that shape the world rely on ESAB’s products and solutions.

How does WireSense work?

The measurement is contact-based via a short circuit without welding and works with all common filler materials. The Fronius welding power source—an iWave or TPS/i—detects edges or joints and transmits this information to the robot controller. The controller compares the data with the programmed path and automatically corrects the tool center point (TCP) so that the seam is always welded exactly at the desired location.

What’s new with WireSense?

• Support for all seam geometries: fillet welds, I-joints, flanged seams, and complex machined shapes
• More flexibility – ideal for companies with varying sheet thicknesses and demanding geometries
• Reliable detection even with thicker materials from 4 mm
• Can be used with steel, stainless steel, aluminum, and CrNi alloys

What is required for WireSense?

The prerequisite is CMT-ready equipment consisting of the Robacta Drive CMT drive unit, the appropriate CMT wire buffer, and the WireSense software package – the CMT software itself is not required.

Integration is carried out via the Fronius welding power source, which transmits the sensor signal to the robot controller at lightning speed. Fronius works closely with robot manufacturers to ensure that the most common robots can process WireSense signals optimally.

Free update for new features

The good news for anyone already using Fronius WireSense is that a free software update is all that is needed to use all the new functions. Tip: An update may also be necessary for the robots used – please check with the robot manufacturer.

Serra Laser will introduce the LightBOT Robotic Laser Welding System at Fabtech 25. LightBOT uses Fanuc CRX co robots and the IPG LightWELD laser welders to produce a cost effective laser welding system that is very flexible. Less than 5 minutes is needed to switch the LightWELD from hand held to co robot mode or back. Retrofittable to any existing LightWELD or can be added new. All functions are controllable from the Fanuc controller and wire welding, fusion welding, spot-tack welding, and laser cleaning can be done. LightBOT can be purchased with or without a LightSAFE or LightCELL laser welding enclosure. The LightCELL can be used for hand LightWELDING or for production welding using the quick switch door – the welder can be outside the enclosure when loading and unloading parts. No knowledge of robot programming is needed with the Fanuc CRX. The Fanuc uses a unique horizontal timeline where the robots arms are moved by hand – a position or LightBOT Icon swiped up to the timeline to memorize the position or tell the robot what to do – such as fire the laser – and the process is followed until the weldment is done. Power can be changed on the fly or any welding condition can modified or called on the fly. For reference the IPG weld mode chart is used and the welder can also use his own preset welding conditions – just like you do by hand. The IPG LightWELD user interface runs directly on the Fanuc tablet. If a welder knows how to LightWELD by hand they can pick up how to weld with the LightBOT within a few hours of training that is done during the on site installation that is standard with the Fanuc LightBOT System. Adaptive Wire Feed Control is available on the Fanuc CRX and this means the welder does not have to try and coordinate wire speed with robot speed. Instead only robot speed is set and this controls the wire speed meaning perfect coordination or wire and motion are attained. For additive applications the ratio of wire to robot speed can be set making it easy to control wire deposition. In development with Fanuc and IPG since 2022 the LightBOT System is running at over 70 users worldwide with the 1st units delivered 2 years ago. Options include multi axis control and up to 2 coordinated axis can be added using Fanuc motors and drives. Turntables, linear rails, or tilt and rotate positioners can be added to the Fanuc system. Wire welding is a specialty of the LightBOT AP and more than one wire feeder can be “on line” at the same time – making switch over of wire type fast. The LightWIRE SERVO wire feeder – single or double, or the IPG wire feeder can be used with the LightBOT. Serra Laser has locations in Michigan, Texas, and California and is IPGs largest dealer for LightWELDs and a Fanuc Authorized Integrator specializing in robotic laser welding applications. We also manufacture the LightSAFE and LightCELL laser welding enclosures. On site installation and training is available with every Fanuc system. Fanuc was chosen as the co robot supplier because of Fanuc support and the 8 year maintenance free design of the Fanuc CRX co robots. The LightBOT system is a result of close collaboration with Fanuc and IPG Photonics and uses the IPG electronic trigger system. Depending on the LightWELD model and Fanuc CRX used a robotic laser welding system is attainable for under $100,000 – a price point never seen before for a laser welder made in the USA – IPG Photonics – combined with the world leader in robotics – Fanuc America. If a potential user already has a Fanuc CRX we can also add our LightBOT SW and HW and create a laser welding system. The LightBOT can be seen in Booth A6581 in the main machine hall at Fabtech 25.We will have two Fanuc CRX robots running the LightBOT System – the 30iA with a 74 inch reach ad the 10iAL with a 55 inch reach. 

The skilled labor shortage is real. But so is the opportunity to reinvent how work gets done. Path’s intelligent welding systems are bringing the future back into focus — and back onto the factory floor.

With Pathfinder, users can perform offline programming in a 3D environment. The software automatically calculates weld paths based on the digital twin and detects potential collisions. This eliminates much of the manual robot teaching traditionally required, which often consumes valuable production time. Instead, programming can take place in parallel while the robot continues operating, maximizing uptime.

Working with digital twins also enables predictive planning. Engineers can test various welding sequences, assess feasibility, and optimize workflows without interrupting production. This leads to faster commissioning, fewer errors, and higher-quality welds. Additionally, the system supports integration with Fronius WeldCube Premium, which ensures complete traceability by linking each weld to its corresponding digital twin data.
Another key advantage is scalability. Whether for small-batch or large-scale production, Pathfinder adapts to different levels of complexity and automation. It supports a wide range of welding challenges and is compatible with many robot brands, making it a flexible tool for modern manufacturing environments.

In an era marked by skilled labor shortages and rising production demands, digital twin technology offers a smart, future-proof solution. Fronius Pathfinder empowers manufacturers to work more efficiently, reduce costs, and maintain high quality standards—ushering in a new era of intelligent welding automation.

Learn more about Fronius Automation and the Pathfinder Software

The Fronius team are looking forward to show their innovative welding solutions at the SCHWEISSEN & SCHNEIDEN trade show in Essen, Stand 3B55, and at FABTECH in Chicago, Stand B29001.

Find out more in these videos

Fronius Pathfinder – Path cloning & simulation

Fronius Pathfinder – CAD import

Fronius Pathfinder – Auto seam & collision detection

Austin Hargett (aka Dr. Weldz), a welder with 14 years of experience and one of the members of Weld.com, tested the ABAGY solution for robot control. He defined welding parameters and put the robot to work without any special knowledge in robotics.

“Welding machines are changing. Technology is changing. My job is a constant evolution. As a welder, I believe that I need to learn something new every day. And I agree with ABAGY that robots can be a new effective tool for welders. I’m really impressed with how simple and easy it was to get the robot up and running.”, – Austin Hargett said.

Also, a poll was conducted among the welding community. Out of 1500 voters, 43% think robots present a great opportunity for better efficiency.

Dmitry Golitsyn, co-founder and CTO at ABAGY, explains: “Every single day we hear from manufacturers that they can’t find people. According to American Welding Society Research, more than 40% of welders are over 45 years old. To address this welder shortage, we can help people who are already in the industry become more productive with new technology”.

Kate Degai, CMO at ABAGY, said: “There’s a prevailing preconception that robots will replace people. This is exactly what hinders the development of robotics. It is impossible to install robots if there are no people inside the factory who are ready to work with them and feel that this helps them to increase their own efficiency. Therefore, we are open to a dialogue with the welding community”.

About ABAGY

ABAGY is revolutionizing the industrial robotics market by extending robots’ applicability to non-serial production. The company breaks the stereotype about robots being applicable only for the mass production of thousands of identical products, such as the automotive industry or electronics. With ABAGY’s software, manufacturers can use robots for custom projects or even one-of-a-kind parts. No robot programming is required.

About Weld.com

Weld.com is a community platform where members can seek advice and network with industry experts. The community has developed a mobile app, and they are also present on social media. Their YouTube channel Weld.com, for instance, has more than 800k subscribers.

High-Performance Robots

Quick axis speeds and acceleration capabilities are key to reducing air-cut time and achieving faster cycle times. Spot welding robots like Yaskawa’s SP-series family of robots are ideal to meeting production and reliability goals, while GP-series robots can be used for existing pedestal welders.

Space-Saving Tools

Floorspace utilization can often make or break competitive edge. Highly flexible seven-axis robots such as the SP100B are specifically designed to maximize floorspace and reach into tight spaces. An expanded range of motion and reduced interference design work together to expertly accommodate high-density workcells. Similarly, six-axis robots like the SP80 or SP165 also offer slim profiles to facilitate product line layout flexibility.

Pre-engineered workcells, like those based on our ArcWorld® series, are also helping manufacturers solve floorspace dilemmas. Robust robots, positioners and process equipment are easily combined with the proper safeguarding on a space-efficient base. Automotive, agriculture, construction manufacturers and more find that these workcells offer a more affordable way to save on cycle time and resources.

Robust Positioners

A wide range of servo positioners exists to provide the speed and reliability needed to get jobs done quickly with the utmost accuracy. From single-axis positioners to three-motor trunnion positioners, and more, a variety of durable options exists to facilitate peak performance.

Manufactured to the same exacting standards as our robots, Yaskawa positioners are built to perform for the toughest applications. A patented MotoMount fixture mounting system allows positioners to be lagged directly to the floor, increasing positioner life and improving weld repeatability. It also simplifies tooling for faster and easier changeover. Multi-tasking software facilitates coordinated motion control between all multi-axis positioners, robots and base axes from a single primary controller and programming pendant.

Servo Guns

Leading spot gun manufacturers like OBARA and ARO work hard to provide their customers with the lightest, most efficient and versatile welding equipment for any material or part size. More energy efficient than pneumatic guns driven with compressed air, today’s servo spot welding guns help:

• Minimize electrode wear, resulting in increased uptime
• Provide consistent clamping force, improving quality
• Eliminate “squeeze time” wait for an air-gun to close, resulting in reduced cycle time

Comprehensive spot welding packages bring all of this to fruition and typically include:

Robust software: spot guns integrated with Advanced Robot Motion (A.R.M.®) control software maximize performance by providing easy calibration for X- or C-type spot guns. They also automate offset for gun arm deflection and tip wear compensation. Furthermore, stepped pressure files allow the spot gun pressure to be varied during the weld cycle, as well as during a tip dress cycle.

Integrated spot gun harness: the spot welding harness improves throughput by eliminating downtime due to robot harness issues and simplified programming. Product launch times can be reduced via simulation and offline programming, versus editing programs to avoid cable interference. New hollow-arm robots increase these benefits even more, and they are equipped with the proper sized wiring for aluminum spot guns.

Efficient servo spot guns: spot gun manufacturers keep packing greater spot gun capability into a smaller system. Transformer sizes have been greatly reduced by using mid-frequency inverters for DC welding. And, higher frequency inverter switching (1,800 to 2,000 Hz) help reduce gun size and weight.

Spot timer digital interface: digital interfaces for spot timers, such as the ones offered by Medar® and Nadex®, allow programming from the robot teach pendant. For the Medar MedWeld 6000 timer, the ability to program and monitor information is also provided with up to to 255 weld programs supported (for each timer). Likewise, up to four timers can be networked with a multiple robot controller.

Overall, all of these technologies work together to provide feature-rich operation that yields transformative results. To learn more on how these items can positively impact your shop floor, contact our experts today!

PMI had experience with Universal Robots’ collaborative robots (or ‘cobots’) following a successful two cobot deployment on mechanical press tending tasks. The deployment was led by Nashville, TN-based Hirebotics, a UR Certified Systems Integrator and pioneer in cloud-connected cobot systems and specialized collaborative welding solutions. 

PMI also had experience with traditional welding robots, which turned out to be unsuited to high mix/low volume production, given that they require tooling fixtures that can take up to 16 weeks to be built. Especially for the small-run parts, traditional robots and fixtures simply weren’t cost-effective.

So, when Larson discovered that Hirebotics offered a complete out of the box, robot welding system that includes a cobot from Universal Robots, the pieces immediately clicked into place. 

“They are collaborative robots and you don’t need a large guarding system around them. They’re very small, easy to use, very easy to program. It’s a win-win package—it’s the future for doing small welds,” says Larson.

To read the full case study, please fill out the form below.

“We are honored to be part of this strategic cooperation with Halter Marine,” said Thomas Bøgner, Sales Director of Inrotech. “To enhance robotic welding solutions with Halter Marine is an important step for both parties, and we are absolutely committed to nothing else than successful operation.

The robots will be integrated and implemented in the Halter marine’s production in order to reduce manhours, increase welding quality and improve productivity. Inrotech’s welding robots usually substitutes 4-5 welders per shift per robot.

Unique Mobile Welding Robots

Inrotech is a Danish company which is born out of the shipbuilding industry and today shipbuilding is still the main market. Instead of huge gantries with large and heavy semi-stationary robots, which were operating in dedicated production areas where the large components were transported in order to be welded, Inrotech chose the other way around: Making small, mobile robot solutions, which can be moved to or even into- the existing production layout.

Without compromising welding efficiency, this solution offered several advantages to the traditional gantry-based solutions: lower cost, less transport of large structures and flexibility to move to different working areas.

Inrotech’s Standard Products

Inrotech’s product-line consist of three standard welding robots. The first product, which has been in operation in shipyards around the world for almost a decade, is the Inrotech-Classic. It is intended for the welding of webs and bulkheads in the shipbuilding industry, yet it can be used for several other purposes as well.

The Inrotech-MicroTwin is a compact and light weight gantry with two welding robots, welding machines and a scanning system for identifying stiffeners on panels. It is specifically designed for the welding of micro panels, sub-assemblies and T-profiles in the shipbuilding industry.

Both robot solutions above are driven by the ‘SensLogic Technology’, representing today a unique technology platform with an unmatched simplicity and user friendliness. Besides being simple to use, you don’t have to transfer any CAD drawings or do any pre-programming, it can also to a large degree obtain tolerances as the reference is the object itself, and not a CAD drawing.

After having placed the panels in the working area; all that has to be done is to push the green start button!

The third product is the Inrotech-Crawler, which is designed for heavy industry for welding of high quality multipass welding’s on site in any position needed. The robot itself is a UR3, which is the smallest of Universal’s robot series.

The robot automatically identifies the welding groove by means of a line scanner and automatically calculates the number of passes, location of each pass, welding speed and weaving pattern; no matter position or plate thickness. Thereby variations in the groove geometry is compensated automatically. The unique technology behind is Inrotech’s own ‘WeldLogic Technology’. It can be used for the welding of almost any weld groove design and in any position- as long as there is physical access for the robot.

Other Markets

“I am pleased that we, as an international frontrunner in advanced welding robots, have entered the American market. Among other things, we ensure an improved competitiveness for Halter Marine, just as we ensure a clearly improved working environment for several welding workers”, says Thomas Bøgner.

“We will now be able to present locally how our robot solutions eliminate heavy and difficult manual welding tasks and thus open up to other potential customers in USA.”

In addition to shipyards, Inrotech’s intelligent and mobile robotic welding systems is the obvious choice for in the offshore industry, green energy sector and manufacturers of heavy-duty steel structures. Inrotech has delivered highly feasible welding robots of wind-towers, steel structures such as bridges and other applications worldwide but also for Hydro plants, welding up to 70mm plate thickness with variations in the groove geometry up to 50%.

The company’s success is based on a unique technology combination of mobile welding automation and a unique software: No programming, simple to use, mobile and flexible and high-quality welding. With the growing demand for quality welding, requirements for improvement of working environment, lack of skilled welders etc., Inrotech see a huge potential market for their robot welding solutions.

About Inrotech:

Inrotech was founded in 2010 by Flemming Jorgensen. Having long working experience with robot technology, an idea for an entirely new paradigm within welding robot technology formed in his mind, while working on a contract for the Maersk owned shipyard “Odense Steel Shipyard” (also called Lindoe). The idea was based on two main conceptual components: First, instead of huge gantries with large and heavy semi-stationary robots, which were operating in dedicated production areas where the large components were transported in order to be welded, why not make it the opposite way around: Make small, mobile robot solutions, which can be moved to- or even into- the work-objects. Without compromising welding efficiency, this offered several advantages to the traditional gantry-based solutions: lower cost, less transport of large structures and flexibility to move to different working areas. Second, no programming. Besides saving time for programming it does not require highly qualified robot engineers.

One of the big advantages of using cobots for a welding application is the ease of programming. SnapWeld was developed with and verified by Universal Robots through the UR+ platform facilitating direct software integration into the UR programming environment, enabling advanced settings to be easily programmed directly on the robot’s teach pendant.