Wireless Safety Control in Automated Robotic Welding

Large-scale fabrication of truck chassis, rail bogies, and heavy equipment demands high-precision arc welding systems. Wiener Neudorf-based igm Robotersysteme AG manufactures custom automation systems and exports 150 to 200 robotic systems annually, centered on the modular RTE 400 platform. These production systems often span extensive manufacturing footprints, requiring operators to program, teach, and monitor weld paths directly inside large fixtures. Traditionally, the primary human-machine interface relied on a wired teaching pendant equipped with heavy industrial cabling measuring up to 50 meters in length.

Eliminating Cable Damage and Trip Hazards
Long trailing cables posed critical operational bottlenecks in heavy production bays. Cables laid across shop floors were vulnerable to mechanical crushing from forklifts and transport dollies. Any internal conductor failure or severed connection within the emergency stop loop triggered an unscheduled shutdown of the robotic cell. Beyond costly downtime and frequent cable replacements, trailing cables created safety hazards for operating personnel moving through expansive welding stations. igm sought a wireless alternative that could maintain strict functional safety standards without sacrificing tactile control elements.

Customized Wireless Architecture and Ergonomics
To resolve these limitations, igm partnered with Salzburg automation specialist SIGMATEK. Building on its established wireless safety platform, SIGMATEK developed a customized variant tailored to igm specifications. The design retained igm's proven ergonomic housing, membrane keypad, joystick, and dual confirmation buttons, while integrating SIGMATEK wireless safety electronics. Operating over 2.4 GHz and 5 GHz bands, safety signals transfer via the Black Channel protocol to an internal SCP 111 safety CPU.




To prevent communication drops in complex metalworking plants, the system incorporates seamless Wi-Fi roaming across multiple base stations. An intelligent login and logout sequence pairs the active emergency stop mechanism exclusively to the assigned robotic cell, enabling one unit to serve multiple stations safely. Built-in power management delivers more than two hours of continuous operation under full electrical load, with battery charging supported during live system setup. Software engineers ported existing Linux control drivers to the Salamander operating system and structured the human-machine interface within the object-oriented LASAL SCREEN environment.

Operational Gains and Field Adoption
Replacing heavy wired tethering with safe wireless communication eradicated line-break stoppages and removed trip risks. Operators gain unencumbered mobility around complex workpieces, streamlining teach-in routines and weld path verification. More than half of igm customers specify the wireless handheld panel for new automated systems, verifying strong demand for reliable, cable-free control in demanding industrial environments.

Edited by Evgeny Churilov, Induportals Media - Adapted by AI.

www.sigmatek-automation.com