CHAIFU Structural Welding Robot Solution: Breakthrough Teaching-Free Welding Technology

Chaifu Robot Co., Ltd. is the only unit in China that masters the closed-loop robot production process from R&D to finished products. The combination of CHAIFU’s robotic arms and mechanical transmission parts with BOCHU’s intelligent control system creates a superior competitive advantage. This helps maintain absolute quality control and optimize costs for businesses in fields such as steel structures, shipbuilding, and non-standard equipment manufacturing.

1. CHAIFU Physical Hardware Structures

Depending on the workpiece size and specific industry requirements (steel structure, shipbuilding, bridges), CHAIFU provides 3 main structural types to optimize space and performance:

Structure Type	Technical Specifications	Optimal Application
Floor-Mounted	SF6-C2080X robot running on closed floor rails.	Workpieces width < 1.1m (Construction steel).
Cantilever	L-shaped reach arm (optional 7, 8, 9 axes).	Workpieces from 1.1m – 3.5m (Bridges, heavy machinery).
Gantry Type	Large gantry crane with 2 inverted robots.	Workpieces > 4m (Shipbuilding, superstructures).

Slide rail robot type

Cantilever robot type

Gantry robot type

2. BOCHU Control System: The centralized “Brain”

The BOCHU system does not just control the robot arm; it is the coordination center for the entire workstation (Workcell).

• Real-time Control (EtherCAT): Synchronous management of robots, welding machines, and peripherals with the lowest latency.

• Multi-axis Interpolation (Up to 18 Axes): Robots coordinate smoothly with axis rails, turntables, and gantries on complex workpieces.

• “Teaching-Free” Technology: Automatically plans paths and welding parameters with a single click, eliminating the need for highly skilled welders.

• Handheld PAD: An intelligent handheld control panel that allows operation directly at the workpiece, saving travel time.

3. Laser-Vision Module: The “Eyes” of the system

To perform automated welding without programming, BOCHU utilizes a dual laser vision system:

3.1. BCW600P Seam Tracker

• Function: Automatically positions the weld seam with millimeter precision.

• Dual Field of View (FOV) Technology: Combines wide-view (coarse positioning) and narrow-view (fine positioning) to find the weld even when assembly errors exist.

• Anti-interference: Operates perfectly in environments with high light intensity and bright welding arcs.

3.2. BCW181P 3D Stereo Camera

• Function: Scans the 3D Point Cloud of actual objects.

• Accuracy: Detects deviations up to ±2mm. This allows the robot to understand the workpiece shape without needing technical drawings.

4. Reverse Modeling Technology: Model-free Smart Welding

1. Real-world 3D Model Reconstruction: Uses the BCW181P camera to scan objects directly on the machining table to create a digital twin.

2. Rapid Production Automation: The robot automatically calculates weld paths based on the scanned model, removing dependence on original CAD files.

3. Practical Application: Especially effective in shipbuilding and bridge construction, where components often lack accurate drawings due to mechanical deformation or manual assembly.

5. FSWELD System Configuration Packages provided by BOCHU for CHAIFU solutions

BOCHU provides flexible solution packages based on business needs:

• FSWELD2800: Standard package (6-7 axis robot, BCW600P sensor).

• FSWELD2800M: Upgraded version, supporting a diverse range of robot models.

• FSWELD3800: Premium version (Full option BCW600P + BCW181P), with comprehensive support for Reverse Modeling.

• FSWELD2800T: Specialized solution for Tower Foot production.

Conclusion: With the deep integration between CHAIFU hardware and BOCHU software, the system provides a perfect automated welding solution. It addresses the challenges of skilled labor shortages and workpiece tolerances in heavy industry.