Key takeaways
- Send production-representative workpiece data, not only a finished-product photo.
- Define cycle time from loading to unloading, including inspection and changeover.
- Separate mandatory requirements from preferences and future options.
- Agree on test parts, acceptance criteria, documentation and handover before the build.
1. Build a production-representative workpiece package
The supplier needs to understand dimensional variation, material condition and how the components arrive at the station. Mark every weld location and show features that affect electrode or clamp access.
- 2D drawings and 3D models with revision status
- Material grades, coatings and thicknesses
- Component tolerances and expected incoming variation
- Weld symbols, joint sections and acceptance criteria
- Representative samples, photos and current-process notes
2. Describe the complete production flow
Cycle time should cover all required operations, not only the welding pulse. Include loading, locating, clamping, welding, cooling, inspection, marking and unloading. State the shift pattern and expected product mix.
| Project area | Questions to answer | Why it matters |
|---|---|---|
| Loading | Manual, conveyor, robot or upstream machine? | Defines interfaces, reach and safety scope |
| Changeover | How many products and how often? | Influences tooling, recipes and mistake-proofing |
| Inspection | What must be monitored or checked? | Defines sensors, data and reject handling |
| Output | Target cycle, shifts and availability? | Guides station count, cooling and buffering |
| Handover | Installation, training and documentation? | Clarifies delivery and acceptance responsibilities |
3. Confirm the welding process before automating it
Automation cannot compensate for an undefined weld process. If the joint is new, schedule process trials before finalizing station architecture. Trials should identify electrodes, force, current, time and the method used to verify the joint.
Fixture design should locate the components without masking normal variation. It should also provide electrode access, manage heat, support maintenance and prevent incorrect loading.
4. Define controls, safety and data expectations
List the required plant interfaces and applicable destination requirements. Avoid adding data collection without a clear use: identify which values operators, quality teams or maintenance teams need and how long records must be retained.
- Destination voltage, air and cooling-water conditions
- Preferred PLC, HMI and industrial network standards
- Recipe access, user levels and language requirements
- Process monitoring, traceability and data export
- Guarding, interlocks and risk-assessment responsibilities
- Factory acceptance and site acceptance test scope
5. Write acceptance criteria into the quotation
Define which parts will be used, how many cycles will be run and which quality, cycle and functional checks determine acceptance. Also identify who supplies samples, consumables, utilities and travel support.
Final system architecture should be validated against the actual workpiece, agreed production target and destination requirements.
