Automated Laser Welding of Pipes

Given three pre-cut mild steel pipes, the task was to design a complete automated production line capable of laser welding them into a single assembly, producing 250 parts per standard working shift. The proposed system featured a 6-axis robot with a fibre laser and vision system, AGVs for material delivery, and custom jigs with hydraulic clamping to handle the welding sequence. Through detailed calculations of laser power, welding speeds, and timing plans, the design achieved 100% utilisation of both the robot and AGV with a cycle time of 115 seconds per part. The project developed skills in automation system design, laser welding theory, robotic process planning, and cost-benefit analysis comparing automated and manual production.