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Machining & forming

Welding Automation

Synchronised motion for positioners, torch axes and welding lines.

  • Typical axes3
  • NetworkEtherCAT
  • Control modeCSP
  • Recommended seriesSDU3 · SM13 · SM10 · SD24-LP
Start Product Selection See the solution
01
The sector at a glance

Welding Automation

In welding automation, positioners turn the part, linear axes carry the torch and the welding speed is held constant along the seam. The arc and high-frequency ignition create strong electrical noise; cabling and grounding are part of the result.

Three things that decide it on the shop floor

  1. 01

    Coordinated speed

    Rotation and torch axes hold one constant seam speed.

  2. 02

    Electrical noise

    Arc and HF ignition make shielding and grounding mandatory.

  3. 03

    Heat and spatter

    Cables around the torch must be protected.

02
Our advantages

Why SMB TECHNICS?

One set, controller to cable

Controller, drive, motor, cable and connector arrive checked against each other; interface problems are solved at the desk, not on the shop floor.

Open standards

EtherCAT, CANopen, Modbus RTU, CODESYS and CiA 402: your machine is not tied to a closed ecosystem.

Engineer-to-engineer support

The same team from sizing to commissioning, on site and remotely.

Documented products

Manuals, CAD, ESI/EDS and firmware in the Document Centre; every product you choose comes with its documents.

Our application know-how for this sector
  • Coordinated speed across positioner and torch
  • EMC and shielding in a welding cell
  • Seam programs and sequencing (CODESYS)
03
How we build the system

From control chain to commissioning, which product goes where

3.1

The control chain and the recommended products

How the machine is driven and the SMB products we choose for it.

In welding automation, positioners turn the part, linear axes carry the torch and the welding speed is held constant along the seam. The arc and high-frequency ignition create strong electrical noise; cabling and grounding are part of the result.

Seam quality depends on the torch travelling at a constant speed and the right angle.

The control chain

Positioner and torch axes are driven over EtherCAT by SD24-LP and SDU3 drives with SM10 motors; a MAT-LC CPU coordinates the axes.

What decides the result

  • Coordinated speed. While the positioner turns, a constant seam speed is held together with the torch axis.
  • Electrical noise. Shielded cables, a 360° shield connection and separate ducts prevent encoder errors.
  • Heat and spatter. Cables and connectors are protected from the heat and spatter around the torch.

Sizing it

We need part mass and inertia, positioner speed, torch stroke and welding speed.

Select the products for this machine Enter power, torque and network; compare compatible drives and motors and add them to your basket. Selection guide
3.2

The architecture: which product goes where

The boxes show the real products; click one to open the series.

EtherCAT Operator panel HMI-R9 Controller · CODESYS MAT-LC CPU I/O and sensors MAT-LC I/O · PNP / NPN Safe stop STO · brake Supply protection EMI · braking resistor Positioner (rotation) Drive · SDU3 CSP · EtherCAT Motor SM13 Positioner (tilt) Drive · SDU3 CSP · EtherCAT Motor SM10 Torch X / Z Drive · SD24-LP CSP · EtherCAT Motor SM08
  • EtherCAT
  • Ethernet
  • Power and feedback
  • Safety
Where this machine sits on the full SMB system map
CPU / PLC & Motion Control 3 series Expansion Rack / IO 10 products Ethernet switch Ethernet Operator Panels 3 series Sensors 3 series EtherCAT Servo Drives 17 products CANopen Servo Drives 6 products Modbus RTU Servo Drives 4 products Servo Motors 6 series Power and Encoder Cables 2 series CODESYS IEC 61131-3 PLCopen Motion Control CiA 402 Drive profile
EtherCAT Ethernet CANopen Modbus RTU Digital I/O Power and feedback

CPU / PLC & Motion Control

Expansion Rack / IO

Ethernet switch

The industrial switch distributes Ethernet traffic between the controller, the operator panel and the engineering PC. It is part of the architecture, not part of the SMB catalogue.

Operator Panels

Sensors

EtherCAT Servo Drives

CANopen Servo Drives

Modbus RTU Servo Drives

Servo Motors

Power and Encoder Cables

CODESYS

SMB controllers are programmed in CODESYS: the IEC 61131-3 languages, integrated motion and a single project covering both machine logic and the axes.

PLCopen

PLCopen Motion Control function blocks give every axis the same standard interface, so proven machine code carries over from one project to the next.

CiA 402

SMB servo drives implement the CiA 402 drive profile: the same state machine and the same operating modes over EtherCAT and over CANopen.

3.3

Product placement, axis by axis

Each axis, its task, its control mode and the drive–motor pair on it.

  1. 01
    Positioner (rotation) Turning the part at seam speed
    CSP · EtherCAT
    SDU3 Drive SDU3 Series Three-phase 380 V AC EtherCAT servo drives with power steps from 400 W to 7.5 kW. SM13 Motor SM13 Flange Family 130 mm-frame servo motors, 220/380 V AC, 1.5–3 kW, with BiSS and incremental encoder options.
  2. 02
    Positioner (tilt) Setting the weld angle
    CSP · EtherCAT
    SDU3 Drive SDU3 Series Three-phase 380 V AC EtherCAT servo drives with power steps from 400 W to 7.5 kW. SM10 Motor SM10 Flange Family 100 mm-frame servo motors, 220/380 V AC, 1–3 kW, with BiSS and incremental encoder options.
  3. 03
    Torch X / Z Carrying the torch along the seam
    CSP · EtherCAT
    SD24-LP Drive SD24-LP Series Flagship EtherCAT low-power servo drive line. SM08 Motor SM08 Flange Family 80 mm-frame 220 V AC servo motors, 750 W–1 kW, with BiSS encoder options and an optional brake.

CSP: cyclic synchronous position · CSV: cyclic synchronous velocity · CST: cyclic synchronous torque · PP: profile position. The series is confirmed by load and supply voltage.

3.4

The build, step by step

From requirement to support; the SMB products and tools each step uses.

  1. 1

    Requirements and sizing

    The motion profile, load and cycle time of every axis are collected; torque, speed and inertia ratio are calculated per axis.

    • Peak and RMS torque, top speed
    • Load-to-motor inertia ratio and gearing
    • Supply: 220 V AC, 380 V AC or 24–70 V DC
    Sizer Selection guide
  2. 2

    Architecture and product choice

    The network (EtherCAT, CANopen, Modbus RTU), the controller and the drive–motor pair per axis are chosen; the safety and power side is drawn at this step.

    • EtherCAT for synchronised axes, CANopen for independent ones
    • Drive current covers the motor peak current
    • STO and braked motors come from the risk assessment
    SD24-LP-04-D1-E SM10-DIN13-100B0 MAT-LC-C06 MAT-SDU3-MP-300-D3-E
  3. 3

    Cabinet, cabling and EMC

    Power and encoder cables run in separate ducts with their shields bonded 360°; an EMI filter goes at the drive input and a braking resistor where the load regenerates.

    • Flexible cable for the cable chain
    • Shields are earthed at both ends
    • The braking resistor is sized from the braking energy
    Power / Motor Cables Encoder Cables SMKP Power Connectors SMKE Encoder Connectors EMI Filters Braking Resistors
  4. 4

    Software and network

    In the CODESYS project the axes are defined with PLCopen blocks; the drives join the network through their ESI/EDS files and run the CiA 402 state machine.

    • IEC 61131-3 languages and PLCopen Motion Control
    • ESI (EtherCAT) and EDS (CANopen) in the Document Centre
    • EtherCAT coupler for remote I/O
    MAT-LC CodeSys CPU MAT-LC I/O Modules MAT-LC System Modules
    CODESYS FAQ Document centre
  5. 5

    Commissioning and tuning

    After wiring and direction checks the gains are tuned and the axes homed; the operator panel carries the machine recipes.

    • Direction, limit and emergency-stop tests
    • Speed and position loop gain tuning
    • Backing up the parameter sets
    HMI-R9 Series
    Commissioning FAQ Troubleshooting
  6. 6

    Support and lifecycle

    Alarm codes, spare parts, firmware and training, from the same engineering team.

    • Alarm-code and troubleshooting guides
    • Manual, CAD and firmware downloads
    • Remote and on-site support
    Technical support Document centre
3.5

The solution package: what comes with the product

Hardware, software, engineering and lifecycle.

02

Software and know-how

The CODESYS project, PLCopen motion blocks and know-how specific to this machine.

  • Coordinated speed across positioner and torch
  • EMC and shielding in a welding cell
  • Seam programs and sequencing (CODESYS)
03

Engineering support

Sizing, architecture, commissioning and tuning, on site and remotely.

  • Motor and drive sizing per axis
  • System architecture and network choice
  • Commissioning, gain tuning and homing
04

Lifecycle

Manuals, ESI/EDS files, spare parts and training.

  • Document Centre: manuals, CAD, firmware
  • ESI and EDS files, parameter backups
  • Spare parts and user training
Engineering knowledge base

Commissioning this application

The topics engineers in this industry ask about most, each with answers, checklists and troubleshooting steps.

Cables and EMC EtherCAT CODESYS Servo alarms

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