The precision manufacturing of high-performance combing drums—often called the "heart" of textile machinery—directly determines the quality of final yarn output. At Trützschler, a global leader in combing machine manufacturing, meeting these extreme tolerance requirements presents unique challenges. Even solid steel plates must maintain exceptional stability at high rotational speeds after machining. This relentless pursuit of precision is now achievable through highly automated production processes.

Combing machines serve as the cornerstone of spinning processes, with their produced sliver quality impacting every subsequent manufacturing stage. Historically, Trützschler relied on manual welding for these crucial drums. While mechanical clamps and joystick-assisted vertical/lateral corrections reduced physical strain, the process remained labor-intensive. In 1999, the company implemented KUKA KR 6 robots while retaining pulse MAG welding technology—a strategic move that not only optimized production but also allowed skilled welders to transition to other departments.

The KR 6 robots operate within an advanced automated cell featuring six-degree-of-freedom mobility, linear drive units, and dual workpiece positioning systems. The setup requires the robot controller to coordinate nine axes simultaneously via CAN bus for precise welding path execution. German system integrator Paul von der Bank GmbH delivered a comprehensive solution including safety enclosures, fume extraction systems, and full functional validation.

To maintain weld quality standards, the robots employ touch sensors for pre-weld "seam finding"—detecting geometric deviations from programmed models—and arc sensors for real-time trajectory tracking during operations. By analyzing arc length variations and current differentials, the system automatically adjusts axis positions to maintain optimal weld pool alignment.

The dual-station design enables continuous production cycles, with one station loading/unloading while the other undergoes robotic welding. Daily output reaches eight drum sets (16 individual drums) in single-shift operation. The system handles two drum variants (1200mm/22mm thickness and 690mm/15mm thickness) with flexible sequencing, completing large-drum welds in 26 minutes (1.1m longitudinal + 7.5m circumferential) and small-drum welds in 14 minutes (4.3m circumferential).

The production sequence begins with CNC flame-cut blanks receiving edge preparation via three-torch rotating units. A magnetic crane then transports formed tubular components to a four-roll bending machine. After temporary spot welding and attachment of run-on/run-off plates (to contain weld defects), the drums undergo robotic longitudinal welding with arc tracking before final circumferential welding of end plates.

Ebenhöh noted significant results: "This cell exemplifies modern manufacturing economics, reducing processing time by 35% versus manual methods while achieving over 95% equipment availability." The company anticipates full ROI within three years, attributing success to localized technical support and responsive service from their system partner.