3D Flexible Welding Fixtures: All-Round Flexible Intelligent Solutions for Multi-Scenario Welding Applications

Overview of the Solution

This 3D flexible welding fixture system centers on “modular combination, full-scenario adaptation, and digital collaboration”. It integrates three core advantages: standardized functional modules, multi-dimensional positioning technology, and open automated interfaces. Specifically designed to address the pain points of traditional welding fixtures—such as high customization costs, low changeover efficiency, and difficulty in adapting to multiple product types—it is capable of accommodating the welding of all categories of workpieces, including box-type parts, frame structures, irregular components, and thin-plate parts.

Covering industries such as automotive manufacturing, construction machinery, wind power equipment, and aerospace, this system achieves the flexible production goal of “one platform replacing hundreds of dedicated fixtures”. It helps enterprises reduce costs by over 30% and increase efficiency by more than 50%.

Core Function System

1. Multi-Dimensional Modular Positioning and Clamping

• Global Flexible Positioning: The top and four side surfaces of the fixture platform are equipped with standardized grid holes (φ16/φ28 series, hole spacing 50/100±0.03mm) and precision scale lines. When combined with components such as positioning squares, V-blocks, and flat squares, it enables 0.05mm-level 3D positioning of workpieces. This allows for the precise fixing of workpieces ranging from 50mm micro-components to 10m large structural parts.
• Rapid Locking System: Utilizing positioning-type quick-locking pins (locking force ≥1.5T), combined with vertical/horizontal spiral clamps and compensating fixtures, workpiece locking can be completed within 30 seconds. The split-type pressure head design offers both anti-slip performance and easy maintenance, capable of withstanding stress impacts caused by welding thermal deformation.
• Multi-Attitude Support Adjustment: Through the combination of supporting components such as U-shaped boxes, height adjusters, and angle adjusters, the system enables arbitrary angle support of workpieces from 0° to 90°. This solves the positioning challenges of irregular components and bevel welds, with a support height adjustment accuracy of 0.02mm.

2. Full-Scenario Welding Adaptability

• Compatibility with Multiple Workpiece Types: Without replacing the basic platform, module combinations can be used to adapt to different structural workpieces, including automotive chassis frames, excavator arm sections, wind power flanges, and stage trusses. It can stably carry workpieces ranging from 1kg thin-plate parts to 50-ton heavy structural components.
• Optimization for Multiple Welding Processes: Tailored supporting modules (such as anti-spatter protective plates, grounding devices, and welding torch guides) are provided for different processes like spot welding, arc welding, laser welding, and robotic welding. The platform surface undergoes nitriding treatment, enabling it to withstand 500℃ high-temperature welding spatter and extending its anti-rust service life to over 8 years.
• Spatial Expansion and Mobile Adaptation: Standard platform sizes range from 800×800mm to 4000×6000mm. Multiple platforms can be spliced into extra-long large workstations using connecting locking pins. Optional support legs with braked swivel casters allow for flexible platform movement and quick fixing, meeting the multi-station scheduling needs of workshops.

Core Composition of the System

Typical Industry Application Cases

1. Construction Machinery Field: Welding of heavy excavator arm sections — By splicing 4 platforms into a 12m workstation, combined with welding robots and positioners, continuous welding of multi-segment welds is achieved. Production efficiency is increased by 50%, and welding deformation is controlled within ≤0.8mm/m.
2. Wind Power Equipment Industry: Welding of flanges and tower barrels for wind power enterprises — A heavy-duty flexible platform with a 50-ton load capacity is adopted, combined with self-centering positioning blocks. The coaxiality error of flange docking is ≤0.1mm, enabling 24-hour continuous production without platform deformation, and fixture costs are reduced by 90%.
3. Aerospace Field: Welding of thin-walled irregular components for aerospace enterprises — Through the combination of fine-tuning supports and compensating fixtures, the problem of thin-plate welding deformation is solved. The part dimensional accuracy is improved from ±0.5mm to ±0.1mm, with a one-time qualification rate of 98%.

Core Competitive Advantages

• Extreme Flexibility and Adaptability: Modular components can be combined into tens of thousands of fixture configurations, covering over 95% of welding scenarios. For small-batch, multi-variety production, the changeover time is ≤1 hour, saving 60%-80% of costs compared to traditional dedicated fixtures.
• Dual Guarantee of Precision and Durability: The basic platform undergoes natural aging + electric furnace annealing treatment to eliminate 99% of internal stress. The positioning repeat accuracy is ±0.02mm, and the normal service life can reach more than 15 years.
• Safety and Compliance: The platform surface features anti-slip treatment and a hidden tool storage design, complying with OSHA safety standards. The entire system has passed CE certification, ISO 9001 quality system certification, and AWS D1.1 welding process standards, making it suitable for global production scenarios.

Full-Dimensional Customization Services

• Basic Customization:
• Size Customization: Platform sizes range from 500×500mm to 10000×8000mm, with load capacities designed on-demand from 5 to 100 tons;
• Hole System Customization: Supports various hole system specifications such as φ16/φ22/φ28, with adjustable hole spacing of 50/75/100mm.
• Functional Expansion Customization:
• Special Fixtures: Design of dedicated positioning blocks and clamps (such as arc-shaped support blocks and pneumatic clamping units) for non-standard irregular components;
• Environmental Adaptation: Provision of special versions such as high-temperature resistant types (withstanding 800℃) and anti-corrosion types (adapting to marine engineering).
• Automation and Digital Customization:
• Turnkey Workstations: Integrated workstations combining robots, positioners, and visual inspection systems;
• Digital Upgrades: Customization of process databases, production monitoring panels, and energy consumption optimization modules.
• Service Guarantee Customization: Provision of on-site installation and commissioning, operator training, 1-year free maintenance, and lifelong technical support. “Regular calibration + rapid repair” service agreements can be signed.