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2025 TAIPEI CYCLE exhibition in Taipei

DS Intelligent Robotic Automated Welding System​

Aluminum Alloy MIG/TIG Automated Welding Solution​

Over 15 years of experience in automated welding, providing professional consulting services, perfectly integrate expertise with advanced technology

Precision Welding · Efficient Production · Smart Manufacturing​

Facing a shortage of welding professionals? Unstable welding consistency? Limited production capacity?​

The global manufacturing industry’s demand for aluminum alloy welding continues to grow, yet many businesses are still limited by challenges such as technical barriers in welding, unstable manual welding quality, and low adoption of automated welding.

With over 15 years of welding technology expertise and automation consulting services, the DS Intelligent Robotic Welding System integrates robotic arm calibration technology, Robotmaster offline programming, and the DS Cloud AI smart manufacturing framework to address the core challenges of automated welding, providing businesses with tailored, high-efficiency, and standardized welding automation solutions.​

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DS Automated Welding Consulting Services​

We not only provide equipment, but also offer professional welding technology consulting to help businesses quickly implement welding automation and ensure smooth production operations:​

  • Welding process and equipment evaluation, developing optimal solutions​
  • Optimization of welding parameters and robot welding paths to improve welding quality
  • Welding jig design and simulation to enhance robot automation welding rate
  • Welding production line integration, from equipment selection to capacity enhancement, one-stop service
  • Combining over 15 years of welding technology expertise with advanced technology to ensure welding quality and production efficiency meet the highest industry standards
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Solution Overview​

We offer two welding automation solutions to help businesses choose the most suitable technology solution based on their needs:​

Full-Featured Version (AVWD-1P / AVWD-2TP)​

  • High precision, highly automated, suitable for both small-batch, high-mix production & mass production
  • Reduces reliance on professional welding technicians, standardizing welding techniques
  • Can integrate with AMR systems and supports automatic mold change design and central control

Budget Version (BVWD-1P / BVWD-2P)​

  • High cost performance, suitable for small and medium-sized enterprises and early stages of automation implementation
  • Effectively reduces welding labor costs and dependence on professional welding skills
  • Offers single and dual station options to meet varying capacity needs
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Full-Featured Robot Welding System

Core Specifications

  • Robot: ABB High-Precision Welding Robot Arm
  • Welding Equipment: Fronius Welding Machine (MIG / TIG options available)
  • Positioner: Single/Dual station options available
  • Safety Protection Mechanism: Complies with CE standards, ensuring welding safety
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Automatic Wire Cutting – Enhances Welding Efficiency & Quality

Automatic Slag Cleaning – Maintains Stable Equipment Operation

Automatic TCP Calibration (Tool Center Point Calibration) – Ensures Welding Precision

Robotmaster Offline Programming – Reduces Welding Path Teaching Time by Over 70%

Cyber-Physical System (CPS) – Integration of Virtual and Physical Systems, Enhancing Production Efficiency

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AVWD-2TP
  • Smart Production Integration
  • Integrates AMR System – Achieves automatic transportation & logistics management, reduces manual handling, and increases production efficiency
  • Supports Automatic Mold Change Design – Quickly switches between different product welding requirements, flexible for small batch and varied production
  • Central Control System (DS Cloud AI) – Achieving remote monitoring & production data analysis
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Real-time monitoring of welding data and equipment status

AI automatic analysis of production data to optimize welding parameters

Enhances factory smart management level and reduces production anomaly risks

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MIG, Pulse Welding

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TIG, Smooth Welding

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AVWD-1P

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Budget Version Robot Welding System

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BVWD-1P

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Core Specifications

  • Robot: ABB IRB1520 Standard Welding Robotic Arm
  • Welding Equipment: Fronius Welding machine (MIG / TIG options available)
  • Positioner: Single/Dual station options available
  • Control System: No PLC / HMI, directly controlled via robot teach pendant

Solution Pricing

  • BVWD-1P (Single station) USD 85,000
  • BVWD-2P (Dual station) USD 100,000

Target Audience

  • Small-scale production companies – Enhance product quality and stability through automation welding technology
  • Companies in the early stages of automation – Providing easy-to-operate automation welding systems, lowering technical barriers
  • Factories aiming to reduce welding labor – Reduce reliance on professional welding technicians, improving production efficiency and consistency
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MIG, Pulse Welding

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TIG, Smooth Welding

DS Welding Jig Design and Simulation – Improve Automation Welding Precision and Consistency

With over 15 years of automated welding experience, welding parameters are tested using scientific methods, optimizing jig design to enhance welding quality and automation welding rates.

Welding Jig Solutions

  • 3D Scanning & Data Simulation – Ensure jig accuracy and avoid customer disputes
  • Optimized Jig Design – Simulate welding paths through Robotmaster to improve welding positioning accuracy and automation welding rates
  • Scientific Welding Parameter Testing – With 15 years of welding experience, test welding parameters to reduce deformation and improve welding consistency
  • Welding Penetration Guarantee and Reliability Testing – Perform fatigue and impact tests post-welding to ensure product durability and stability

Welding Jig Design, Simulation, and Manufacturing

Design jigs based on product geometry, verify accuracy through 3D scanning and Robotmaster simulations, ensuring high match rate and automation welding rate, reducing errors and disputes

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Precision Design × Intelligent Verification, ensuring the robot's automation welding rate is close to 100%, achieving ultimate stability and efficient production!

Welding Jig Design Pricing Plans

The number of jigs required for the welding automation system is adjusted based on product structure and welding requirements, ranging from 2 sets to 5 sets or more. We offer three levels of welding jig solutions, allowing customers to select the most suitable configuration based on production line needs and automation level.

Basic Jigs

2,000-4,000 USD

No welding path simulation

Only basic clamping and positioning design

Requires customers to adjust parameters themselves to increase welding automation rate

Robot Path Optimization Jigs

5,000-7,000 USD

Through Robotmaster welding simulation ensure accurate welding positions

Welding automation rate can exceed 90%

Based on these results, conduct module disassembly design to improve production flexibility

Welding Parameters + Path Optimization Jigs

13,000-18,000 USD

Through Robotmaster robot welding path simulation, confirm that the welding automation rate exceeds 90% and optimize the robot's motion trajectory to improve production efficiency.

Welding parameter adjustment and verification using scientific methods for testing to ensure weld seam consistency, reduce deformation, and improve weld strength.

Material preparation consultation services providing suggestions for pipe, casting, forging and other pre-welding treatments, helping to provide the best design and modification suggestions to improve welding feasibility and stability.

Welding penetration rate testing and verification using professional testing equipment for weld penetration depth tests, post-weld fatigue tests, and weld seam strength inspections to ensure weld seam durability and compliance with industry standards.

Welding jig designs best suited for high-standard product manufacturing, helping businesses establish stable welding quality standards.

  • Jig Quantity and Automation Efficiency:The number of jigs required for the welding system is adjusted based on product structure and production line needs, typically ranging from 2 to 5 sets or more, ensuring optimal automation efficiency.
  • Welding Simulation and Jig Optimization:Through Robotmaster, welding simulation and jig optimization are performed to enhance welding accuracy, stability, and production efficiency.
  • Application of Experience and Scientific Methods:Combining 15 years of robotic automated welding experience with scientific methods ensures welding consistency, reduces deformation, and improves weld strength and quality stability.
  • Industries and Application:Suitable for aluminum alloy welding applications, such as bicycles, automobiles, aerospace structures, and metal manufacturing industries, meeting various industrial needs.
  • Automation Rate and Influencing Factors:The welding automation rate can exceed 90%, but the actual level of automation depends on product design and jig configuration. The final welding automation rate will be confirmed based on product requirements, testing results, and environmental evaluations.
  • Jig Design and Accuracy Verification:Jigs will be designed based on the geometric requirements of the client's product, and after jig manufacturing, 3D scanning will be used to verify jig accuracy to ensure high compatibility with the welding system and reduce disputes.
  • Welding Functions and Quality Standards:This solution ensures welding functions and weld seam penetration rates, but the details of weld seam appearance (such as weld bead uniformity, surface smoothness, etc.) need to be adjusted by the client according to product requirements to meet the final quality standards.
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Professional Testing – Providing Scientific Evidence for Bicycle Frame Welding Quality

We offer comprehensive bicycle frame testing services, equipped with advanced testing instruments and professional consulting support. Our testing covers the following aspects to ensure the durability and safety of your frame during use:

  • Fatigue Testing:This test evaluates the durability of a bicycle frame under prolonged repetitive loading, simulating various stresses and forces experienced during actual riding. The testing process involves multiple cycles of loading and unloading to replicate repetitive movements during riding, ensuring that the frame does not develop cracks or fail over long-term use.
  • Impact Testing:Impact testing assesses how a bicycle frame responds to external shocks, such as falls or collisions. It ensures that the frame can withstand sudden impacts and maintain its structural integrity, particularly in critical areas like the front fork.
  • Static Strength Testing:This test measures the ability of a bicycle frame to withstand a single large load while stationary. It ensures that the frame can endure the maximum weight load encountered during riding without deformation.

Modular Bicycle Frame Automatic Welding Production Line – Efficient, Intelligent, Standardized Manufacturing​

DS Modular Frame Welding Production Line uses fully automated welding technology combined with 3D laser cutting, intelligent welding systems, and AMR automated transport to create a high-capacity, low-labor dependency, standardized quality smart manufacturing solution.

Capacity Conditions

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Working Conditions

  • Daily working hours: 24 hours
  • Monthly working days: 22.5 days
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Production Shifts

  • Three shifts
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Standard Frame

  • Cycle Time: 3 minutes/unit
  • Annual production capacity: 129,600 units
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E-Bike Frame

  • Cycle Time: 5 minutes/unit
  • Annual production capacity: 77,760 units
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Production Line Overview​

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24-hour continuous production with three shifts operation to ensure high production capacity output

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The entire line uses automated welding and 3D laser cutting technologies to ensure high precision and consistency

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Equipped with the AMR automated logistics system to reduce manual handling and improve production efficiency

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Suitable for both standard bicycle and electric bicycle frames, supporting diversified product manufacturing

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Production Line Technology Highlights

3D Laser Cutting Zone

Front Triangle Frame Spot Welding Zone

Front Triangle Frame MIG Welding Zone

Front Triangle Frame Cooling Zone

Front Triangle Frame TIG Smooth Welding Zone

Rear Triangle Frame MIG & TIG Smooth Welding Zone

Frame Assembly Welding Zone

AMR Automated Transport

Intelligent Handling System Design

Production Line Advantages

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Fully Automated Welding

Ensures stable welding quality, reduces manual intervention, and improves welding consistency

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Standardized Production Process

Data-driven production to shorten welding cycles and increase output capacity

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Intelligent Logistics Integration

AMR automated handling reduces manual handling costs, minimizes human errors, and enhances production flow efficiency

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Diverse Application Support

Suitable for a variety of products, including standard bicycles and electric bicycle frames, with the flexibility to adjust automation levels based on customer requirements

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Intelligent Management and Data Analytics

Paired with the DS Cloud AI intelligent management system, providing real-time monitoring, data analysis, and welding parameter management to ensure stable line operation and traceability of quality

6

Rich Experience in Mass Production Design

With multiple successful cases, we have provided mature automatic welding solutions for international brands, ensuring the best industrial manufacturing standards

6 Reasons to Adopt the DS Robotic Welding System Now

Ultra-High Precision Welding – Ensuring Quality Consistency

Welding Automation Rate Over 90% – Reducing Labor Costs and Increasing Production Capacity

Intelligent Logistics Integration – Making Your Factory Smarter

High Flexibility – Meeting Welding Needs Across Industries

Quick Return on Investment (ROI) – Low Risk, High Return

Professional Technical Support, Over 15 Years of Welding Experience, For a Safer Adoption!

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