Panasonic Factory Solutions has implemented its TAWERS G4 Welding Robot System for STADLER Anlagenbau, a manufacturer of specialist systems for turnkey recycling and waste sorting plants. This automates manual welding processes, vastly reducing welding cycle times, and increasing production line efficiency and scalability.
Credit: Panasonic
Reduced Cycle Times a Priority
With all systems and components manufactured in-house, STADLER currently uses Panasonic G3 systems to manage all welding on the conveyor belt frame system, pre assembly, and actual assembly. The integrated welding source, broad process range (MIG/MAG, Puls-MAG, CO2), and Panasonic’s intuitive Weld Navigation software provides high flexibility while maintaining stable quality.
The new G4 Welding Robot System optimises welding process management into a single controller for high-quality arc welding. It features improved controller processing power, higher axis speeds, and optimised controller-robot communication. The G4’s high-resolution touchscreen simplifies programming, with enhanced contact tips delivering superior welding quality and reliability. This removes the need for increased spares storage and minimises maintenance downtime.
Prior to installation, STADLER undertook extensive simulations, and test welds at Panasonic’s Robot & Welding Test Centre in Neuss, with employees given specialist training to maximise the G4’s functionality.
"Panasonic’s robot welding systems are easy to operate and maintain. As a result, the cycle and throughput time for some products, including all preparation, has been reduced to one-third of the original time. Aside from scheduled maintenance cycles, the G4 has exhibited faultless reliability since installation. If any questions do arise, support is always quickly available when required, providing peace-of-mind,” comments Bruno Stützle, Head of Production at STADLER.
Virtual Production Planning and Simulation
STADLER uses Panasonic’s offline Desktop Programming & Simulation (DTPS) software across its production line. This provides remote digital access to real-time production and system operating data, allowing it to simultaneously plan and simulate manufacturing processes. This increases production flexibility, saving valuable time and resources.
DTPS can also directly input CAD data (in multiple formats) into the production line. Component geometries can be easily adapted, while features such as collision detection, cycle time calculation, and welding parameter optimisation significantly improve quality and efficiency.
“Panasonic’s DTPS offline programming software enables us to simulate and optimise production processes in the planning phase. This saves time and reduces the risk of errors and required rework," adds Stützle.
A Gateway to Global Expansion
The addition of a third TAWERS Welding Robot System has vastly increased STADLER’s production efficiency. This provides it with the scalability to expand internationally into new regions, and explore new business opportunities in electronic waste and clothing recycling.
Panasonic will exhibit its TAWERS G4 Welding Robot System in Hall 9, Booth 9505 at Schweisstec 2025, between 21st-24th October. To read the full case study, please visit: https://eu.connect.panasonic.com/gb/en/case-studies/manual-welding-automation