When this configuration makes sense
- ✓Long structures and welds spread along the part
- ✓Serving several workstations in one line
- ✓Processes where the arm’s reach alone does not cover the whole part
WS kit + linear track
Welding cobot on a linear track
A cobot on a rail - a larger working area without moving the cell.
An external linear axis enlarges the cell’s working area so it can handle long parts and several workstations. The 2 m track is synchronised with the robot controller. We match the WS cobot model to the kit - any model in the family fits. The actual working area depends on the cell geometry and part fixturing, not on the track length alone.
- • Delivery of a ready-made kit
- • On-site training
- • 5 years of technical support included in the kit price
Track length
2 m
Arm payload
3–30 kg
Arm reach
622–1900 mm
External axis
Linear, synchronised
Who it is for
Long structures and several workstations
Plants welding parts longer than the reach of a single cell, or serving several workstations with one robot. The track eliminates moving the cobot by hand between work points - the arm travels to the next workstation within a single, synchronised cycle.
When to choose a different solution
- -Cells without space for safe axis travel
- -Processes that mainly require part rotation
- -Cases where the part can more simply be repositioned or re-clamped
Operating principle
The cobot travels to the weld, not the other way round
The board shows the process sequence. Below is what decides whether that sequence can be repeated on your structure.
- The linear axis as part of the program
- The controller treats the track as another robot axis, so travel and arm motion form one cycle, not two separate operations.
- Cell geometry
- Welderstal assembles the track and aligns its geometry. This determines whether the program points stay consistent along the whole length of travel.
- Access along the whole route
- The part, fixtures and equipment must leave the torch access in every carriage position, not only at the starting point.
The key limitation
The track length does not add to the arm’s reach. 1900 mm is the cobot’s reach and 2 m is the travel distance - the actual working area is calculated for a specific part and cell.
Design
What the track is built from
The rigidity and repeatability of travel come from specific components. They are what distinguish a machine axis from makeshift shifting of the cell.
- Load-bearing structure
- High-rigidity ITEM system aluminium profiles, with a dedicated set of bolts and mounting elements
- Guidance
- High-load linear guides
- Drive
- Servo drive with a matched torque and a precision mechanical gearbox, transmitting the drive via a pinion to a toothed rack
- Cable management
- Cable carrier (e-chain) protecting power and signal cables in motion
- Assembly
- Complete mechanical assembly and precise alignment of the track geometry by Welderstal
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Scope of delivery
What makes up the cell
The board shows where each component sits in the kit. The list below is the scope of delivery - stated openly, so that a complete cell is not confused with the cobot arm alone.
In the configuration
- ✓WS cobot arm matched to the process - with power supply, safety button and control box
- ✓Cobot base matched to the arm: PIN 28 system in the WS-5 WML kit, magnetic foot or PIN 28 in the WS-5 kit
- ✓Smart tool, manual seventh axis and adjustable torch holder
- ✓5 m MIG/MAG cable, control panel and Welderstal welding plugin (PL/EN)
- ✓Delivery, commissioning, operator training and certification appropriate to the cell
- ✓5 years of technical support included in the kit price
- ✓2 m track made of ITEM profiles, linear guides, servo drive, gearbox, toothed rack and cable carrier
- ✓Installation, calibration and synchronisation of the axis with the robot controller
For assessment or selection
- -Part fixtures, guarding and cell layout require assessment
- -The scope of implementation engineering depends on the size and layout of the cell
- -The MAG power source is selected separately
Choosing the cobot
Which cobot goes into the kit
Any cobot in the WS family fits the welding kit. We match the model to the part, reach and cycle time - the rest of the kit stays the same.
WS-3
Fairino FR3
- Payload
- 3 kg
- Reach
- 622 mm
Magnetic foot or PIN 28
WS-3 WMS
Fairino FR3-WMS
- Payload
- 3 kg
- Reach
- 622 mm
PIN 28 system
WS-3 WML
Fairino FR3-WML
- Payload
- 3 kg
- Reach
- 922 mm
PIN 28 system
WS-5
Fairino FR5
- Payload
- 5 kg
- Reach
- 922 mm
Magnetic foot or PIN 28
WS-5 WML
Fairino FR5-WML
- Payload
- 5 kg
- Reach
- 1900 mm
PIN 28 system
WS-10
Fairino FR10
- Payload
- 10 kg
- Reach
- 1400 mm
PIN 28 system
WS-16
Fairino FR16
- Payload
- 16 kg
- Reach
- 1034 mm
PIN 28 system
WS-20
Fairino FR20
- Payload
- 20 kg
- Reach
- 1854 mm
PIN 28 system
WS-30
Fairino FR30
- Payload
- 30 kg
- Reach
- 1403 mm
PIN 28 system
Cell base
The cobot base determines repeatability
On the track the cobot is mounted to the carriage, but the same kit also lets you set it up off the track. In that case the base depends on the chosen arm.
What this means in practice
The kit with the WS-5 WML arm works on PIN 28 locating pins - with a 1900 mm reach, a magnetic foot cannot hold the cell base. The kit with the WS-5 can also use the magnetic foot, which can be moved to another steel surface without tools. We show both variants on the basic kit page.
Choice of external axis
Linear track or positioner
Both configurations add an external axis to the cell, but they solve different problems. The difference comes down to what has to move: the cobot or the part.
| Criterion | Linear track | Positioner |
|---|---|---|
| What moves | The cobot along a linear axis | The part on a rotary axis |
| Typical part | Long structures, several workstations in one line | Pipes, sleeves, shafts, flanges |
| Effect on the process | Larger working area along the axis | Welding without refixturing between sides of the part |
| Mechanical base | ITEM profiles, toothed rack and gearbox | Self-centring chuck Ø10–300 mm, continuous rotation |
| Control integration | Synchronised with the robot controller | Synchronised with the robot controller |
Both versions are based on the same arm and the same Welderstal welding plugin, so the choice does not change how the cell is programmed. The difference concerns only the process geometry.
Cell data
Track length is only the start of selection
Based on these six pieces of information we check the actual working area, the workstation layout and torch access along the whole travel route.
01
Part length
Dimension along the travel axis
02
Number of workstations
How many workstations one cobot is to serve
03
Space for travel
Free space along and around the track
04
Weld layout
Distribution of welds along the structure
05
Part fixturing
Fixtures, datum surfaces and tolerances
06
Material and process
Thickness, weld type, MAG parameters
FAQ
Questions about the linear track kit
Which cobot goes into this kit - WS-5 WML or WS-5?
Your choice. The WS-5 WML is based on the Fairino FR5-WML arm with 1900 mm reach and ±0.1 mm repeatability. The WS-5 is based on the FR5: 922 mm and ±0.02 mm. The rest of the kit is the same, and we match the arm to the part size and required accuracy.
How does the cobot mounting differ between the two versions?
We supply the WS-5 WML kit on PIN 28 locating pins. With a 1900 mm reach a magnetic foot cannot hold the cell base, so it is not used in this version. The WS-5 kit can work on a magnetic foot or on the PIN 28 system.
Does the kit include commissioning and training?
Yes. The scope covers preparing and commissioning the kit, operator training, certification appropriate to the cell and 5 years of technical support included in the kit price.
Does the 2 m track increase the cell’s reach to 3900 mm?
We do not publish such a total. Reach is given by the arm - 922 mm for the WS-5 or 1900 mm for the WS-5 WML - and 2 m is the track length. The actual working area depends on geometry, fixturing and cell constraints.
Next step
Describe the structure and the cell layout
Give us the part length, number of workstations, space available along the track and the weld layout. On that basis we will calculate the actual working area and check the cell geometry.
Send part details for selection