When experience drives innovation, it often looks like the collaboration between Vecoplan and Valk Welding: two companies with strong technical expertise joining forces to rethink production processes. At the heart of their joint project is a fully automated robotic welding cell for the production of rotors – the core component of many recycling machines. Handling, positioning, welding and even the complex hardfacing process are now automated at Vecoplan – thanks to a precisely coordinated system of two robots, intelligent software and integrated safety measures.
As part of the ‘Rotor production with a robotic welding system’ project, an intensive and comprehensive market analysis was carried out to select suitable suppliers. Five potential candidates were identified and evaluated in detail.
In order to arrive at a well-founded decision, the project team carried out an analysis based on criteria such as technical performance, service quality, level of innovation, cost-effectiveness and implementation expertise. Two suppliers achieved almost identical overall scores, which made the final choice challenging.
To confirm the internal analysis, an independent assessment was requested from an external institute. At the same time, in-depth discussions were held with the two selected suppliers to take additional qualitative aspects into account.
After completing all evaluations and discussions, Valk Welding was selected. The decisive factors were the company’s professional and competent approach, as well as its convincing presentation of technical solutions and project processes.
The implementation phase fully confirmed this choice. Valk Welding proved to be an extremely reliable and powerful partner. The collaboration was – and still is – efficient, solution-oriented and focused, clearly demonstrating that the right choice was made.
‘Valk Welding convinced us not only with its technical expertise, but also with its reliability and genuine partnership. The collaboration clearly showed that we had chosen the right partner – both professionally and personally.’
Valk Welding impresses as a partner
As part of the ‘Rotor production with a robotic welding system’ project, an intensive and comprehensive market analysis was carried out to select suitable suppliers. Five potential candidates were identified and evaluated in detail.
In order to arrive at a well-founded decision, the project team carried out an analysis based on criteria such as technical performance, service quality, level of innovation, cost-effectiveness and implementation expertise. Two suppliers achieved almost identical overall scores, which made the final choice challenging.
To confirm the internal analysis, an independent assessment was requested from an external institute. At the same time, in-depth discussions were held with the two selected suppliers to take additional qualitative aspects into account.
After completing all evaluations and discussions, Valk Welding was selected. The decisive factors were the company’s professional and competent approach, as well as its convincing presentation of technical solutions and project processes.
The implementation phase fully confirmed this choice. Valk Welding proved to be an extremely reliable and powerful partner. The collaboration was – and still is – efficient, solution-oriented and focused, clearly demonstrating that the right choice was made.
Martin Selbach emphasises:
‘Valk Welding convinced us not only with its technical expertise, but also with its reliability and genuine partnership. The collaboration clearly showed that we had chosen the right partner – both professionally and personally.’
Rotor production reinvented – From handling to wear protection
Rotors are among the most heavily loaded components in shredders. Their production requires maximum dimensional accuracy, precision and – especially when applying wear-resistant material – in-depth knowledge of materials and processes. Until now, many of these steps were carried out manually at Vecoplan. Skilled welders ensured quality, but the process was time-consuming, labour-intensive and difficult to scale.
This led to the desire to automate the process – not with a conventional robot solution, but with a holistic, scalable system that fully integrates and autonomously performs handling, welding and wear protection. This is exactly what has now been achieved in collaboration with Valk Welding.
The solution: Twin robot system with storage tower and smart welding concept
At the heart of the system is an arrangement of two cooperating welding robots, supplemented by a central storage tower for tool holders. This configuration enables fully automated production:
· Robot 1 ensures the precise positioning of tool holders from the storage tower. A specially designed gripper ensures correct alignment and safe transfer to the rotor, after which Robot 2 secures them.
· Once the components are fixed in place, both robots start the welding process simultaneously – a highly productive approach that significantly reduces cycle times.
A particular highlight is the welding process itself: in addition to conventional MAG welding, the system also performs fully automated hardfacing – a process that is normally done manually due to the high demands on positioning accuracy, layer thickness and repeatability. Both robots now perform this task simultaneously, without compromise.
Software as the key: QPC programming based on design data
A decisive success factor was software integration. Valk Welding implemented its own QPC – Quick Programming Configurator, a parametric offline programming solution that automatically generates welding programmes based on design drawings.
Instead of manually teaching each robot position, geometry is interpreted directly from the CAD drawing. This saves a tremendous amount of time – especially with new variants, series changes or different rotor dimensions. The flexibility of this solution enables Vecoplan to efficiently automate even small series or single pieces.
Safety and ergonomics: Workplace protection integrated
Modern automation goes beyond robotics. Safety and environmental requirements are integrated into the system design from the outset. The installation at Vecoplan includes integrated torch extraction and a large-scale extraction system with an extraction hood. Welding fumes, particles and gases are captured directly at the source – an important contribution to occupational safety and regulatory compliance.
Cooperation on an equal footing: Vecoplan & Valk Welding
The project was realised through close cooperation between the automation experts at Valk Welding and the process engineers at Vecoplan. Both partners worked in iterative steps, with realistic simulations and short decision-making lines – from the initial design to commissioning.
“From idea to success – with friends in a great team! Together, across borders, we achieved our goal. It was a real pleasure to be part of this. A big thank you to Dortmund and Alblasserdam! Here in Westerwald, we are enthusiastic about the new system – and we are already looking ahead: with new ideas and further cooperation with Valk Welding. Glückauf – here’s to new opportunities and innovations!” says Klaus Weinbrenner, Head of Welding at Vecoplan.
“This project was one of last year’s technological highlights and impressed many visitors to our facility. It also convincingly demonstrated what is possible when two partners work together openly, honestly and as equals – in the spirit of our motto: The Strong Connection,” adds Christian Hüser, Sales Director at Valk Welding.
Technology partners at a glance
Vecoplan AG, based in Bad Marienberg (Germany), is a global leader in machines and systems for reducing, transporting and processing primary and secondary raw materials. With more than 500 employees, the company offers solutions for the recycling, plastics, wood and waste industries.
Valk Welding B.V., headquartered in Alblasserdam (NL), is a technology leader in the field of robotic arc welding systems. In addition to hardware, Valk Welding offers innovative software solutions, comprehensive service and modular production cells – specifically tailored to medium-sized companies.
‘Glückauf’ is a traditional German miners’ greeting, meaning ‘good luck’ or ‘come back safely’. It expresses hope for success and a safe return.
