20kg Payload 1820mm Reach 6-Axis Arc Welding Workstation for Heavy Fabrication

Overview

This arc welding workstation is built around the KR 20 R1820-2 E, a 6-axis arc welding robot with a 1820mm reach and a 20kg payload. The long arm covers full-length welds on frames, beams and shells without repositioning the fixture, so one welding station can serve two clamp positions instead of one and the operator loads while the torch is still working.

A 20kg payload carries a water-cooled torch, wire feeder, collision sensor and cable package without exceeding the rated load. Because the motion profile is tuned to the rated 20kg rather than the theoretical maximum, travel speed and weave amplitude stay consistent through a full shift. A 32kg maximum payload is available where the centre of mass sits on the flange axis and the load case is verified in KUKA.Load or KUKA Compose before commissioning. On a heavy fabrication line this 20kg payload and 1820mm reach combination is what allows one fixture to hold a long weldment.

On an arc welding workstation, bead geometry depends on repeating the same torch position every cycle. A pose repeatability of ±0.03 mm to ISO 9283 holds torch angle and stick-out steady, which matters on multi-pass work where a drift of a few tenths of a millimetre shows up as an uneven cap, poor tie-in or lack of fusion. The same repeatability keeps the arc welding workstation stable when fixtures are swapped between product variants, and it keeps a 6-axis arm honest after years of production.

Spatter, fume and grinding dust are the normal working conditions for a welding arm. The body carries IP54 protection and the wrist carries IP67 to IEC 60529, so the wrist drives stay shielded from spatter and fine dust. The 6-axis industrial robot arm can be mounted on the floor, ceiling or wall at the desired angle, and a 1820mm reach arc welding workstation gains most from ceiling mounting: it lifts the arm out of the fume plume and frees floor space for fixture loading, while angled wall mounting lets the workstation sit inside a narrow cell beside a positioner.

The 6-axis arc welding workstation runs on the KR C5 S 6/S7 or KR C5 slim-2 controller with a KUKA smartPAD-2 or smartPAD touch plus pendant. Program backup, fieldbus integration and torch cleaning routines follow the standard KUKA workflow, so a maintenance team already running KUKA equipment can support the station without a separate platform. At roughly 255 kg and a 430 mm x 370 mm footprint, the arm suits a pedestal, gantry or column design, and it operates between 0 °C and 55 °C.

Key Specifications

Advantages

• A 1820mm reach lets one 6-axis arc welding workstation cover a long frame seam or two clamped parts, cutting fixture moves per shift.
• 20kg payload covers torch, wire feeder, collision sensor and cable package together, with axis speeds up to 592°/s on A6 for fast air moves.
• ±0.03 mm repeatability keeps torch angle and stick-out identical between passes, which supports consistent cap height on multi-pass welds.
• IP54 body and IP67 wrist reduce spatter and dust damage to the wrist drives, so the 6-axis arm survives unshielded cells.
• Ceiling and wall mounting remove the arm from the fume path and release floor space for fixture loading.
• KR C5 controller family keeps spare parts, welding interfaces and diagnostics inside the standard KUKA service chain.
• Compact 430 mm x 370 mm footprint simplifies pedestal, gantry and column designs.
• Rated payload tuning keeps welding speed and weave consistent over long production runs.

Applications

• Long-seam welding of structural steel frames and beams
• Tank, silo and vessel shell welding with a positioner
• Heavy fabrication of chassis, booms and machine base weldments
• Two-station fixture welding where the arc welding workstation alternates between clamps
• Ceiling mounted 6-axis welding on gantry and overhead rail cells
• Repair, rework and patch welding on castings and fabrications

Frequently Asked Questions

Q: What makes this a welding workstation rather than a plain robot arm?
A: The cell is specified around welding duty: a 20kg payload 1820mm reach arm for torch, feeder and cable package, IP67 wrist protection against spatter, a 1820mm reach that covers long seams, and a KR C5 controller prepared for welding interface and torch cleaning routines.

Q: How much torch and cable weight can it actually carry?
A: Rated payload is 20kg for the combined tool load, which covers most water-cooled torch packages with feeder and collision sensor. A 20kg payload 1820mm reach arc welding workstation therefore runs a full torch package without de-rating the motion. Send us the tool bill of materials and centre of mass, and we will confirm the duty point before quotation.

Q: How does 0.03mm repeatability affect weld quality?
A: Repeatability of ±0.03 mm on all 6-axis keeps the torch at the same position and angle from part to part. On multi-pass welds this avoids cap height variation and lack of fusion caused by the torch drifting between passes.

Q: Can the workstation be installed above the fixture?
A: Yes. Floor, ceiling, wall and angled mounting are all supported. On a 1820mm reach arc welding workstation, overhead mounting is common where fume extraction sits low or floor space is needed for loading.

Q: What protection level does the wrist have?
A: On this 6-axis arc welding workstation the wrist is IP67 and the body is IP54 to IEC 60529. In heavy spatter zones we recommend a torch cleaning station and a protective cover on the arm as well.

Q: Which controller and programming platform are used?
A: The 6-axis arc welding workstation uses the KR C5 S 6/S7 or KR C5 slim-2 controller with a KUKA smartPAD-2 or smartPAD touch plus pendant. Programs, backups and fieldbus setup follow standard KUKA practice.

Q: What is the lead time and shipping format?
A: Stock units ship within 7 working days; configured welding builds take 30 to 45 days. Each arc welding workstation ships in an export wooden crate with shock-proof foam, moisture barrier and sea-worthy bracing.

Ordering Notes

Send us the part envelope, seam length, fixture layout and torch package weight. We will confirm reach coverage, payload margin and mounting orientation for the cell, then quote the 20kg payload 1820mm reach arc welding workstation with delivery and shipping terms.