Innovation isn’t just about technology – it’s about the people who make it work. MASPRO believes that the real power of automation lies in its collaboration with human expertise.
Enter Andrew Brown, Samrat Adhikari, and Bertha (MASPRO’s Fanuc robotic arm-equipped X-wing welding positioner).
Together, they are redefining MASPRO’s welding process, combining cutting-edge automation with deep technical knowhow to improve efficiency, precision, and product durability.
The challenge: transitioning from manual to robotic welding
Switching from traditional manual welding to robotic automation wasn’t as simple as flipping a switch.
One of the biggest challenges was adapting the welding process to Bertha’s capabilities. Unlike human welders, robotic systems require precise part positioning, specialised jigs, and advanced programming to execute perfect welds consistently.
Andrew had to rethink the welding approach, ensuring that Bertha could replicate the same high-quality results as a skilled human welder but with increased efficiency.
Meanwhile, Samrat worked with MOSES, a software application used for simulating robotic weld paths, offline programming, and generating weld sequences for Bertha. The learning curve was steep, but the results have been game-changing.
The power of through arc seam tracking (TAST)
MASPRO’s robotic welding system utilises TAST (through arc seam tracking) to adjust for slight variations in joint position during welding. This ensures consistent weld quality by making real-time corrections
The shift to pulsed transfer: stronger, cleaner welds
Another significant improvement has been the transition from short circuit transfer to pulsed spray transfer. This switch has drastically improved the integrity of MASPRO’s welds by:
- Reducing spatter: short circuit transfer generates excess spatter, leading to more cleanup and potential defects. Pulsed transfer minimises this, ensuring a cleaner weld with less material waste.
- Controlling heat input: since MASPRO works with heat-sensitive materials like chrome rods and quench and tempered metals, maintaining precise heat input levels is critical. Pulsed transfer provides a better heat input through the use of it as a second lower background current, preserving the mechanical properties of welded components.
- Increasing weld strength: more precise control over heat input and penetration results in stronger, more durable welds, enhancing the longevity and reliability of MASPRO’s products.
Faster production, higher quality
Before Bertha joined the team, welding a single front centraliser frame took 240 minutes. Today, with robotic automation and refined welding processes, that time has been cut to just 100–110 minutes per frame – a staggering 50 per cent reduction.
This efficiency gain allows MASPRO to produce more components in-house, reducing reliance on subcontractors and giving us greater control over quality and turnaround times.
Read the full blog here and learn how MASPRO’s precision engineering solutions are supporting mining operations across Australia and beyond.