Fori Automation, USA implemented a welding system for an SUV aluminum front suspension sub frame. The integration of weld scanning in North American automotive welding systems required an economical and robust concept to offer original equipment manufacturers (OEM's) European style weld verification and high system thru put. For this project Fori provided Robotic Aluminum MIG Welding, a Robotic Fori Weld Check System and In-line Inspect/Repair Stations.
Weld seam inspections for U.S. Automotive Structural Components are becoming a developing requirement to ensure critical welds are free of defects. Current weld seam inspection systems are not cost effective in North American markets due to high on-set costs and high levels of good part rejections that result in added production labor costs and lost production thru-put.
Current weld seam scanning inspection systems operate with extreme resolution to detect very small defects and weld bead profile conditions required to provide reliable weld certification. This results in high numbers of acceptable welds that are rejected due to the high accuracy image-processing requirement.
Fori Automation and a North American customer developed Weld Check as an alternative to high-resolution weld seam scanning systems. We combined low cost, high-speed 2D profile weld seam scanning and electronic data from the digital welders in a common database to provide reliable weld seam accept/reject capability. The combination provides customers with cost effective and truly efficient weld verification.
The solutions provided on this project offered high robot utilization and keyence profile scan and fronius weld database. Results eliminated part handling and the 100% weld check and allowed for 54 assembly jobs per hour (JPH) with a capacity of 40,000 lbs. or 18,181 kg. This weld project was successful due to the in-line robotic weld check system and the integrated sub-assemblies. To learn more about this project or Fori's welding systems check out our site.
A high production capital welding system for large truck frames require efficient transfer and handling systems to maintain production thru-put. Close-coupled direct feed systems for major sub components (rails), and AGV’s integrated into end of line processes, help provide flexible facility configuration and efficient production flow.
Fori Automation recently supplied a high production robotic welding line with 150 robots (114 MIG welding and 36 transfer), inline inspect and repair stations, inline buffers, over aisle transfer conveyors, 8 AGV’s with frame positioner trunnions, 3 inspect/repair platform stations, and final frame stacking cell.
The weld system provided flexible tooling and welding processes for 35+ models of pickup and SUV frames with multiple wheelbase variations, and multiple drivetrain, body and box configurations. The AGV’s were built by Fori Automation, USA.
The complete welding system was built, runoff and delivered from Fori Automation de Mexico—Arteaga, Coahuila.
Increased demand for air ride suspension required a new system with higher capacity. Multiple canister weld cells are required due to the continuous welds for leak requirements, which feed into integrated final assembly and testing cells for consistent quality.
The robotic weld system consisted of six weld cells with ten aluminum MIG welding robots, two material handling robots, and four rotary welding stations for continuous pressure tank welds. Additionally, two final assembly welding stations for mounting brackets and two final assembly stations for pressure valves, fittings and labeling.
The mezzanine provides for overhead location of robot controllers, welders, and system control panels to reduce overall plant floor space.
In-line leak test stations provide verification of the finished product.
Highly flexible, automated robotic MIG welding assembly cells, consists of (3) similar lines that accommodated customers (9) different model variations.
The rear suspension cradle satisfies approximately 90% of the vehicles in this family, with its model output accurately controlled and monitored throughout each robotic weld line.
Each line possesses (21) MIG welding robots, (3) material handling robots and utilizes a minimum number of operators. The current assembly system runs consistently between 181 seconds and 150 seconds depending on which model is being processed. After completion of the robotic welding, the critical component characteristics are machined with a pair of precision, custom machining centers.
The integration of the MIG welding and material handling robots has decreased cycle time and increased throughput. Utilizing highly accurate machining stations and a repeatable process has also reduced waste and the quality of the final product has been greatly increased
Fori Mexico provided a robotic MIG and projection welding system for a sub frame line for an automotive manufacturer.
Features:
Assembly Cycle Time: 54 seconds
Keys to Success: Integrated robots and custom designed turn tables, custom precision welding
Results: Decreased cycle time, increased quality
https://www.youtube.com/watch?time_continue=120&v=yKQiLvi-SyU
The front sub-frame line has a total capacity of 292,000 units with a cycle time of 54 seconds. The assembly consists of MIG welding, projection welding and clinch studs. Fori processed this with dial tables mounted to the customer's base system for ease of installation.
The assembly line consists of 22 MIG welding robots and ten material handling robots. MIG welding is the main process completed, but the line also has Vitronic cameras to scan welds for quality control, post welding pierce stations, and machining centers for key attachment points and a map vision system to verify dimensional accuracy.
Fori USA was responsible for project management and engineering for the program. Fori Mexico was responsible for building the line, debug and run off on their floor. The robotic welding system proved to be a successful collaboration between Fori USA and Fori Mexico. The ability to support the setup, buyoff and installation near the customer plant was of great value to the end user.
For more information about Fori Automation's welding systems, please visit our website.
The Robotic MIG Welding system contains resistance spot welding, projection welding, drawn arc welding and a sealer application.
https://www.youtube.com/watch?v=yKQiLvi-SyU
Features:
Assembly Cycle Time: 54 seconds
Keys to Success: Integrated robots, custom designed turn tables, custom precision welding
Results: Decreased cycle time and increased quality
The robotic weld system provided accommodates for multiple structural end item assemblies that consisted of resistance spot welding, projection welding, drawn arc welding, as well as a sealer application. The system contained multiple welding cells with a total of (50) robots.
The end item assemblies within this program were Load Beams, Rear Quarter Inner, Rear Closure Inner Assembly, Dash Assembly, Cowl Side, Center Floor Pan Assembly and Sill Outer.
Dial indexers where integrated into a number of the weld cells to improve the efficiency of the robots. Within the process some robots carried weld guns while others were material handling robots that moved the assemblies through pedestal welders (spot, projection and drawn arc) or pedestal sealers.
Fori USA was responsible for Project Management, Engineering, Assembly and Integration. All cells were setup and run off at Fori's global headquarters in Shelby Township, MI. Fori Mexico was responsible for installation and buy off at the end user's production facility.
For more information on Fori Automation's weld lines, please visit our website.
Fori Mexico recently broke ground on a new headquarters that provides over 70,000 square feet of production space. The new facility includes manufacturing and office space to support the continued growth of Fori Automation.
The new facility was built to support the continued growth of Fori Mexico. Over the past 3 years Fori has experienced a substantial amount of growth within its Fori Mexico division.
Fori Automation broke ground on the new Fori Mexico facility in January of 2019.
Fori Mexico currently has over 50 employees and a plan is in place to hire over 20 more within the next three years. Pictures of the new facility and start of the project can be found below. The new facility is located in Coahuila, Mexico.
The new facility will support the continued growth of Fori Mexico.
Fori Automation is a global designer and builder of Material Handling, Assembly, Testing and Welding Systems. For more information on Fori Automation's products and locations, please visit our website.
Fori Automation recently expanded its Global Headquarters with the addition of a new 50,000 square foot facility. The new facility includes manufacturing and office space to support the continued growth of Fori Automation.
The new facility was built to support the Welding Business Unit and its customers. Over the past 3 years Fori has experienced a substantial amount of growth within its Robotic Welding Business Unit. The Welding Business Unit focuses on Automated MIG, Projection and Spot Welding for the Automotive Industry.
Fori Welding Business Unit Team
Thanks to the addition of 55 new employees during 2017 and the added manufacturing space we will be able to better support our global customers. With the addition of 55 new hires in 2017, Fori USA now has over 260 employees at its Global Headquarters and over 650 globally. Fori is continuing to add members to the team in order to support the growth of the organization, to view open positions click here.
Robotic Welding System for a Large Truck Frame
The new facility is located across the street from Fori Automation's Global Headquarters in Shelby Township, MI.
Fori Automation's New 50,000 Square Foot Robotic Welding Facility
Fori Automation is a global designer and builder of Material Handling, Assembly, Testing and Welding Systems. For more information on Fori Automation's products and locations, please visit our website.
Fori recently supplied a highly flexible, automated robotic MIG welding assembly system. The system consisted of three similar lines that were able to accommodate nine different vehicle model variations.
The rear suspension cradle for the project satisfied approximately 90% of the vehicles in the family. There was a high level of importance on ensuring process control, the product had to be accurately controlled and monitored throughout each robotic weld line.
Each automated weld line possesses (21) MIG welding robots and (3) material handling robots. The current assembly system runs between 150 and 181 seconds depending on which model is being processed. After completion of the robotic welding, the critical component characteristics are machined with a pair of precision, custom machining centers.
Automated Robotic MIG Welding System
The integration of the MIG welding and material handling robots has decreased cycle time and increased system throughput. Utilizing highly accurate machining stations and a repeatable process has also reduced waste and the quality of the final product has been increased.
The system resulted in the following benefits to the end user:
Decrease in total cycle time
Reduced infrastructure to handle product variations
Increase in product quality
Main keys to success included the integrated robots, custom designed turn tables and the custom, precision machining centers.
For more information on Fori's available equipment, please visit our website or contact us at sales@foriauto.com.
Fori recently supplied an automated assembly and robotic weld cell that processes a complicated cradle assembly consisting of numerous parts and sub-assembly components.
Each line supplied utilizes 10+ MIG welding robots and additional robots for material handling. The system goal was to utilize a minimum number of operators. The current assembly system include a strict cycle time. Due to the complexity of the assembly, Fori was required to utilize excessive processing skills and use "outside of the box" thinking to develop a complete solution.
Fully Automated Robotic Weld and Material Handling System
After completion of the robotic welding, the critical component characteristics are formed with precision hydraulic pierce units and is followed up with a dual station machining center. Once assembled, the assembly enters a CNC validation and deburring station, followed by a vision inspection system to verify and track part quality. A video on Fori Cradle Welding Systems can be found here.
Through the utilization of experienced resources, Fori was able to develop a viable process. The utilization of the MIG welding and material handling robots has decreased the total cycle time, increased throughput and ensured consistent product quality.
For more information on Fori welding systems please visit our website.
Each line possesses (21) MIG welding robots, (3) material handling robots and utilizes a minimum number of operators. The current assembly system runs consistently between 181 seconds and 150 seconds depending on which model is being processed. After completion of the robotic welding, the critical component 
characteristics are machined with a pair of precision, custom machining centers.
The integration of the 
The assembly line consists of 22 MIG welding robots and ten material handling robots. MIG welding is the main process completed, but the line also has 
Fori USA was responsible for project management and engineering for the program. 
Fori USA was responsible for Project Management, Engineering, Assembly and Integration. All cells were setup and run off at Fori's global headquarters in Shelby Township, MI. Fori Mexico was responsible for installation and buy off at the end user's production facility.
For more information on Fori Automation's weld lines, please visit our 
