Stud Welding and Comprehensive Solutions
Over the years in our workshop, we’ve seen how many projects become complicated because they try to be solved with generic equipment. The reality is that in stud welding, when facing long production runs, complex geometries, or specific regulations, you need more than just buying a machine.
Our process begins with an on-site study where we evaluate the parts, the plant, and production cycles.
Automation of Welding Processes
Our specialty: automating the complicated.
When production runs are long and you can’t afford failures, robotization is the only viable answer. Here we’ve set up robotic cells for clients who needed to weld hundreds of identical studs, with zero variations. Where we’re most demanded is in railways: we developed a complete system for bogies that not only welds with precision but documents every parameter – the exact time, amperage, pressure – to comply with EN 15085. The trick is that the robot and the welding machine “speak the same language,” synchronized to the thousandth of a second.
When the part doesn’t cooperate: tooling that solves the impossible.
What if the problem isn’t welding, but access? We’ve experienced this with automotive subchassis where it was physically impossible to place the studs manually. The solution was motorized tooling with multiple movement axes that present the part in the perfect position for each weld. But be careful: not just any design will do. Structural calculation is key. If the tooling can’t withstand the necessary pressure or allows minimal flexing, the weld fails. We test everything in CAD and then manufacture it here, in our workshop, where we can control every last detail.
Own Manufacturing Capabilities
Our ability to manufacture allows us to maintain total control over each project. We have a workshop equipped with a horizontal CNC machining center and CNC lathes for manufacturing precision components. The assembly bay, with 700 square meters of open space and two 10-ton overhead cranes, allows us to work with large and complex components. All this is complemented by a specific pre-assembly area where we perform dimensional and functional verification before final delivery.
Integrating these systems into existing production lines additionally requires developing specific communication interfaces. We’ve implemented solutions with Profinet and Ethernet/IP protocols that allow centralized control from the master PLC and data collection for MES systems, thereby contributing to the improvement of the OEE (Overall Equipment Effectiveness) of the facilities.
A Team of Specialized Engineers
Each project follows a structured methodology spanning from initial analysis and conceptual design, through detailed engineering and manufacturing, to final commissioning and validation. Our team of engineers specialized in mechanical calculation and CAD design works in close collaboration with production technicians, ensuring that each solution not only meets the technical requirements but is also manufacturable and maintains the required quality standards.
Are you evaluating how to optimize your stud welding processes?
Our engineers are prepared to analyze your specific case and develop a technical solution adapted to your real production needs.
Con más de 40 años de experiencia en el sector de la soldadura y las técnicas de unión Bearcat extiende sus conocimientos a todos los sectores industriales: automoción, ingeniería de ferrocarriles, ingeniería industrial, industria naval, obra civil.
