In today’s structural steel fabrication industry, companies are increasingly challenged by the limited availability of skilled labour for layout and welding operations. These tasks are traditionally labour intensive and require highly experienced workers to interpret drawings, measure steel members and manually mark the layout locations for secondary components.

Through a collaboration between FICEP S.p.A. and AGT Robotics, advanced robotic solutions are available to automate these complex fabrication processes.

The FICEP SABRE and FICEP E-LEXINGTON systems combine robotic welding with intelligent layout technology to automate the most labour-intensive operations in structural steel fabrication.

This powerful combination can achieve productivity levels equivalent to 6–8 employees performing manual layout and welding operations.

A&S Machinery Sales supplies structural steel fabrication machinery throughout Australia and New Zealand, supporting fabrication companies seeking greater automation and production efficiency.

Automation for Structural Steel Fabrication

Traditional structural steel fabrication requires skilled workers to read fabrication drawings, measure steel members and manually mark the locations of detail items using tools such as measuring tapes, squares and soapstone.

The FICEP robotic layout and welding systems eliminate these manual processes by automatically transferring digital fabrication data directly to the steel member.

This automation ensures:

• Faster production cycles

• Improved fabrication accuracy

• Reduced reliance on skilled labour

• Consistent production quality

FICEP SABRE Robotic Welding System

The FICEP SABRE is an advanced robotic welding system designed to automate the welding of secondary components onto structural steel members.

The system performs robotic welding of all secondary attachments on the main structural member, significantly reducing the time required for manual welding operations.

During operation, the operator loads the structural section after the detail items have been tack welded in the correct positions. The member is placed into automated welding positioners where the SABRE system performs the welding process automatically.

Because structural steel sections are subject to normal rolling tolerances, the SABRE system uses advanced sensing technology to detect the exact position of the steel surfaces before welding begins.

This allows the robotic welding process to be generated automatically without manual adjustment by the operator.

Key Advantages

• Automated welding of secondary components

• Intelligent surface sensing technology

• Compensation for steel rolling tolerances

• Consistent weld quality

• Reduced manual welding labour

• Increased fabrication productivity

Detail Item Probing

Before the robotic welding process begins, the SABRE system probes the actual location of the tacked detail items on the structural member.

This probing process ensures that the robot accurately detects the precise position of each component, allowing the welding path to be automatically adjusted to compensate for fabrication tolerances.

Benefits

• Accurate component detection

• Compensation for fabrication tolerances

• Automatic welding path adjustment

• Improved weld accuracy

• Consistent welding results

Two-Zone System for Continuous Production

The SABRE system can be configured with a two-zone tandem working system to maximise productivity.

While the robot performs welding operations on one structural member, the operator can simultaneously tack weld detail components onto the next member in the second work zone.

Once welding is completed, the positioners rotate and the robot immediately begins welding the next prepared member.

Advantages

Continuous production workflow

• Reduced machine idle time

• Faster fabrication cycles

• Improved productivity

Integrated Welding Positioners

The SABRE system can incorporate automated welding positioners that rotate and position the structural steel member during the welding process.

These positioners ensure that the robot can access the correct welding positions without requiring the operator to manually rotate the section.

Benefits

• Automatic rotation of structural members

• Optimal welding positions

• Reduced manual handling

• Improved welding efficiency

FICEP E-LEXINGTON Automated Layout System

For decades, structural steel fabricators have faced the challenge of finding, training and retaining employees capable of performing accurate manual layout operations.

The FICEP E-LEXINGTON eliminates the need for manual layout by automatically projecting layout information onto the steel member.

Instead of reading drawings and manually marking locations using measuring tools, the system automatically identifies the correct layout positions directly from digital fabrication data.

This automation ensures that layout information such as component locations, welding codes and fabrication details are applied accurately and consistently.

Advantages of Automated Layout

• Eliminates manual layout marking

• Removes the need to interpret drawings manually

• Improves layout accuracy and repeatability

• Reduces labour requirements

• Increases production efficiency

Laser Profile Identification

The E-LEXINGTON system uses advanced laser profile identification technology to determine the position and orientation of the structural steel section.

The laser scanning system automatically locates the steel member and establishes the reference zero point required for accurate layout projection.

Benefits

• Automatic detection of section position

• Accurate reference point identification

• Compensation for steel rolling tolerances

• Precise layout projection

Detail Item Projection

Once the steel profile has been identified, the system projects the required layout positions of secondary components directly onto the steel member.

This visual guidance allows operators to easily position components in the correct locations prior to tack welding.

Advantages

• Accurate placement of detail components

• Clear visual guidance for operators

• Faster preparation of members

• Reduced layout errors

Detail Item Tack Welding

Using the projected layout information downloaded from the 3D fabrication model, the welder positions the detail components onto the main structural member and performs tack welding.

Because the layout information comes directly from the digital model, component placement is highly accurate and consistent.

This process prepares the structural member for the automated robotic welding operations performed by the SABRE system.

Processing Capability

Available Process

• Robotic welding

Section Shapes Processed

The FICEP SABRE and E-LEXINGTON systems can process a range of structural steel sections used in fabrication.

Structural Steel Sections

• Beams

• Angles

• Flats

These systems are commonly used in fabrication workshops producing structural steel components for buildings, bridges, industrial plants and infrastructure projects.

Structural Steel Fabrication Machinery

A&S Machinery Sales supplies a complete range of structural steel fabrication machinery, including:

• CNC beam drilling machines

• CNC angle processing machines

• Plate processing machines

• Robotic beam coping systems

• Steel marking machines

• Shot blasting systems

• Robotic welding systems

Our machinery solutions help fabrication companies improve automation, productivity and manufacturing efficiency.

Request More Information

If you would like more information, please contact A&S Machinery Sales.

Our team will be pleased to assist in selecting the most suitable machine for your requirements.