Automated resistance spot welding

For spot welding, also known as resistance spot welding, we at KUKA offer optimally matched and quickly available automation solutions for economical robot-controlled spot welding with high quality weld and short cycle times.

Innovative spot welding technology: from individual robots to complete systems

In spot or resistance welding, high mechanical pressure is applied to a relatively small area and a large amount of energy is applied in the form of an electric current. During the weld process, two electrodes press sheets of metal together and convert the welding current into heat at the metals contact surface, as a result of which a permanent fixed joint, or spot weld, is created between the two metal sheets.

KUKA offers cost-effective and high-quality spot welding solutions for resistance spot welding, even for customer specific weld requirements. Our product's short delivery times enable individual solutions for the automation of spot welding - from welding robot arms with high payloads and optional additional axis to complete spot welding lines with perfectly matched components.

Automated welding with KUKA: The advantages

KUKA's automated process of forming a weld combines maximum speed with exact weld precision, ensuring the best weld quality of welded joints and maximum efficiency throughout the welding process.

Accuracy

KUKA's robotic arms fitted with electrode end of arm tooling weld extremely precisely with a high repeatability and resistance spot weld accuracy.
Speed

Automated resistance spot welding takes place at a typical speed of 1.5s per spot or faster.
High availability

Standardized products with short delivery times and proven technology ensure maximum availability.
Full Set-up

KUKA offers perfectly combined technologies such as welding software and robotic peripery.

High-precision robotics for resistance welding of steel or aluminum workpieces

KR IONTEC ultra

The welding robot excels particularly in resistance spot welding with lightweight welding guns.

Payload: 90 - 120 kg
Maximum reach: 2305 - 2702 mm

KR QUANTEC

The spot welding robot joins sheet metal, aluminum and steel in top quality and at maximum speed for short cycle times.

Payload: 300 kg
Maximum reach: 3904 mm

KR FORTEC

The robust and reliable heavy-duty robot for precise spot welding impresses with its low operating costs.

Payload: 240 - 500 kg
Maximum reach: 2800 - 3750 mm

Secure new or used spot welding robots now with high load capacity and long arm reach!

KUKA.ServoGun: Control of spot welding guns

KUKA.ServoGun is a comprehensive software package for resistance spot welding, which increases process stability and efficiency by integrating the servo gun as a robot axis. Integrated assistance functions ensure quick and easy commissioning.

The welding software offers optional extensions for special materials and the highest quality requirements. It automatically controls the servo-controlled gun, communicates with the system and monitors quality criteria as well as water and air conditions.

KUKA.RoboSpin: Spot welding of aluminum joints

Resistance spot welding of aluminum is carried out with high process forces and welding currents, which means that the surfaces of the electrode caps are subject to heavy wear. This leads to high contact resistances, which means that frequent cap milling is required to prevent the caps from welding to the components. The KUKA.RoboSpin solution, which significantly improves the service life of the electrodes between the milling processes, provides a remedy. During the welding process, the welding gun performs a rotational movement around the center of the welding spot, which leads to improved control of the contact resistance. The software thus reduces cap wear and significantly increases process stability when spot welding aluminum.

The spot welding robot rotates the servo gun during welding, significantly increasing the service life of the electrode caps

KUKA.EqualizingTech: Simple gripper equalization

KUKA.EqualizingTech enables the compensation of component tolerances through robot movement and without additional components - for lower maintenance requirements, reduced overall weight and lower maintenance costs.

Compensation of material defects during spot welding with servo-controlled guns.

Download the software for the spot welding application in my.KUKA!

Welding aluminum? No problem! Score high now in production for electromobility.

Aluminium plays an important role in e-mobility because of its ideal combination of lightness and strength. In welding and joining processes, the material aluminum can withstand high demands. With comprehensive process know-how and the right products, KUKA prepares you for the technological transformation towards e-mobility. The example of the battery box shows how the use of robots enables the production of aluminum components at a high quality level in a short time.

Would you like to automate your welding process?

Benefit from expert advice on all aspects of automated welding - tailored to your application. Discover models of spot welding robots with different ranges and load capacities, new or used, for maximum flexibility in your production.