4-Axis Automated Welding System Design
This project is a 4-axis automated welding machine designed for welding circular steel frame assemblies with high accuracy and repeatability.
The complete system was designed in SOLIDWORKS, including all mechanical components, fixtures, motion systems, and assembly integration.
This machine was fully designed in SOLIDWORKS, manufactured, assembled, and successfully commissioned for industrial production. The video included in this portfolio shows the actual machine operating in a production environment.
Project Scope
Complete machine concept and mechanical design
Dual-station rotary fixture system
Custom welding fixtures
4-axis gantry motion system
Structural frame and machine enclosure
Manufacturing drawings and assembly documentation
Design for manufacturability and easy maintenance
Machine Features
4-axis motion system (X, Y, Z + Rotary Axis)
Ball screw driven linear axes
Linear guide rail system
Servo motor driven positioning
Automatic welding torch positioning
Two independent welding stations for increased productivity
Safety enclosure with transparent protective panels
Adjustable fixture system for accurate part positioning
Modular machine construction
Custom Fixture Design
A dedicated fixture was designed specifically for the circular welded assembly.
Fixture features include:
Multiple quick toggle clamps
Precision locating pins
Concentric positioning system
Stable support for repeatable welding
Easy loading and unloading
Distortion reduction during welding
The fixture securely holds the inner and outer circular tubes together while maintaining dimensional accuracy throughout the welding process.
Welded Part
The workpiece consists of:
Outer circular tube
Inner circular tube
Radial connecting bars
Center mounting plate
Support brackets
The fixture guarantees consistent positioning of every component before welding begins.
Mechanical Design
The machine includes:
Welded steel base frame
Heavy-duty gantry structure
Precision linear guide rails
Ball screw transmission
Servo motor drive system
Cable carrier management
Welding torch mounting mechanism
Protective guarding
The overall design focuses on:
High rigidity
Precision positioning
Easy maintenance
Industrial reliability
Long service life
Software Used
SOLIDWORKS
Assembly Design
Weldments
Sheet Metal
Motion Layout
Technical Drawings
Deliverables
Full 3D CAD Assembly
Part Modeling
Fixture Design
Manufacturing Drawings
Assembly Drawings
BOM (Bill of Materials)
Exploded Views
STEP / Parasolid / SOLIDWORKS Files (if required)
Short Description (CAD Crowd Portfolio)
4-Axis Automated Welding System with Dual-Station Fixture
Designed a complete 4-axis automated welding machine in SOLIDWORKS featuring a dual-station rotary fixture, precision ball screw linear axes, servo-driven motion system, custom welding fixtures, and a fully enclosed industrial frame. The project includes complete mechanical design, fixture development, manufacturing drawings, and production-ready assemblies optimized for high repeatability and industrial welding applications.