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Large-Format FSW System for Structural Components in Rail Vehicle Manufacturing

For large-format aluminium structural components in rail vehicle manufacturing, HAGE realized FSW gantry systems.
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Components produced include side walls, door frames, wheel arch supports, connection pins and end cross members. The systems are designed for 2D and 3D FSW welding and operate in two stations in shuttle mode.

An additional FSW spindle unit from below enables simultaneous welding from above and below. This eliminates the need to turn large-format components while also improving flatness, process reliability and takt time. The system features process monitoring, an RPT tool interface and a flexible basis for different component variants.

Technical Data

  • Gantry system with 130 kN and 6 axes
  • Additional lower spindle unit with 20 kN and 2 axes
  • System dimensions: approx. 40 x 12 x 7 m
  • Upper FSW spindle: max. 3,000 rpm, axial force 130 kN, radial force 80 kN
  • Lower FSW spindle: max. 6,000 rpm, axial force 20 kN, radial force 10 kN

Highlights

  • FSW gantry systems for large-format structural components
  • Simultaneous welding from above and below
  • Shuttle operation for high system availability
  • HAGE tool interface for retractable pin and combined FSW tools
  • Automatic tool change also for RPT tools
  • FSW process monitoring with HAGE WeldCheck
  • Flexible expandability for different components