U759 / U769 AUTOMOTIVE WELD CELLS
Automotive Manufacturing – Body Structures Assembly Equipment
What We Did
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Electrical controls design for 3 robotic weld cells
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PLC and HMI programming
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Weld control configuration and integration
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Full commissioning and startup support at system integrator facility
System Details
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9-robot weld cell
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4-robot weld cell
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1-robot weld cell
Why It Mattered
Delivered stable, production-ready weld cells across multiple configurations under tight program timelines
PLANT SAFETY CONTROL SYSTEM UPGRADE
Hydrogen R&D / Industrial Facility Safety
What We Did
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Safety controls engineering for plant-wide safety functions
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Safety PLC programming and integration
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Safety IO integration (Gas monitoring sensors, flame detectors, smoke detectors, safety control valves, emergency stops, etc.)
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Network integration and commissioning support
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On-site testing, validation, and bring-up support
System Details
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Safety-focused control architecture for facility equipment and zones
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Integrated safety devices and field wiring into a centralized safety system
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Designed for maintainability, troubleshooting, and future expansion
Why It Mattered
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Improved safety reliability and operational confidence in a high-risk environment while maintaining practical serviceability for day-to-day operations.
CONTROLS RETROFIT –
AUTOMATED PROJECTION WELDING SYSTEMS
Manufacturing Retrofit / Legacy Equipment
What We Did
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Complete controls retrofit of 14 automated nut welding machines
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Re-integrated salvaged components from scrapped and decommissioned equipment
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Integrated mixed IO and communication architectures, including ControlNet, DeviceNet, IO-Link, and hardwired systems
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New PLC and HMI implementation with standardized control logic
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Commissioning, debugging, and process stabilization
System Details
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14 production-critical nut welding machines
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Hybrid legacy and modern control architecture
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Standardized operator interfaces and diagnostics across all machines
Why It Mattered
Extended the life of existing equipment and avoided full machine replacement, saving the customer approximately $4.25M while improving reliability, consistency, and long-term serviceability