Robotic wire twisting and welding cell

Feeding, stripping, twisting, spot welding, testing and sorting – in one automated cell with a cycle time under 20 seconds.

About the project

We designed and built a universal cell for series production of twisted wire assemblies for an industrial customer. The cell takes two wires from spools, strips and twists them, and a robot arm then carries each part through spot welding, forming and resistance testing.

Every part is tested automatically and sorted as good or reject, while the operator follows the process on a single touchscreen. The project was developed together with Defense Systems Ltd.

How it works

1. Feeding

Two wires unwind from spools with adjustable speed and even tension.

2. Stripping and twisting

The machine cuts, strips and twists both wires using our own twisting module.

3. Robot

A Dobot MG400 cobot picks each part and moves it between stations.

4. Welding and testing

Spot welding, resistance measurement and automatic sorting into good parts and rejects.

Cell modules

Wire feeding

Stripping and twisting

Dobot MG400 robot

Spot welding

Technical data

Cycle time per part	18–20 s
Resistance measurement	0–40 Ω, accuracy ±0.1 Ω
Sorting	automatic – good / reject
Robot	Dobot MG400 (collaborative)
Welding	Styler PDC4000A, spot welding
Control	own software, touchscreen PC, camera
Power supply	220 V, max. 1 kW
Compressed air	6–7 bar

Our own software

Programs for different lengths, manual and automatic modes, good/reject counters, live resistance readings and a camera view.

The cell in operation

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