Heavy-Load Welding Breakthrough | ESTUN CLOOS Laser Hybrid Welding Empowers Intelligent Manufacturing Across Multiple Industries

In automotive and heavy equipment manufacturing, heavy-load thick plate welding is a key process that determines product strength and reliability. Whether it is commercial vehicles, construction machinery booms, heavy trucks, mining machinery, or rail transit equipment, large-size and thick-specification components have long faced pain points such as cumbersome traditional welding processes, large workpiece deformation, and low production efficiency, restricting the intelligent upgrading of production lines.

As a wholly owned subsidiary of ESTUN, CLOOS, a "hidden champion" in the welding industry with a century of heritage, is deeply engaged in the field of intelligent welding for medium and thick plates, creating mature laser hybrid welding turnkey solutions for multiple industries. Recently, CLOOS joined hands with Juntong to implement a complete intelligent robot automated welding production line for commercial vehicle booms, delivering a benchmark answer for heavy-load welding manufacturing.

The welds of commercial vehicle boom components can reach up to 12 meters in length, with plate thickness up to 12 mm. Traditional processes require double-sided operation and repeated correction, resulting in low production efficiency. This project adopts the CLOOS QRC 60PL series welding robot system, equipped with an IPG 12 kW dual-channel laser, and integrates a hybrid welding head, laser sensing, and intelligent control modules, achieving integrated intelligent manufacturing from plate processing to finished weld inspection. It realizes single-sided welding and double-sided forming, simplifies processes, and avoids deviations caused by secondary welding.

The production line welding speed can reach 150-185 cm/min, and welding efficiency is 4-5 times higher than conventional processes. It can complete batch production of 7-12 meter long welds, with a welding qualification rate of over 98%. The production line covers workpiece weights from 30 kg to 2 tons, adapts to 4-12 meter booms, and can weld 3-8 mm plates. Relying on full penetration welding capability, the heat-affected zone is extremely small, the workpiece is nearly free of deformation, the weld has no spatter and requires no grinding, eliminating secondary processing steps and breaking through the industry's technical bottleneck in boom manufacturing.

In fact, the demand for heavy-load welding is spread across the hardcore fields of the national economy: booms and turntables of construction machinery, frames and axles of heavy trucks, giant equipment of mining machinery, car bodies and bogies of rail transit... Wherever there are thick plates, long welds, and high strength, there is the battlefield of heavy-load welding.

Relying on ESTUN's deep accumulation in robotics and intelligent manufacturing, combined with CLOOS's century of welding process heritage, CLOOS provides turnkey solutions of "robotics + welding processes + intelligent production lines" for various industries—from process validation to production line delivery, replicating capabilities verified in the commercial vehicle industry to broader manufacturing scenarios.

From process R&D to production line implementation, ESTUN and CLOOS continue to tap the potential of intelligent welding manufacturing, using mature automation solutions to help the domestic equipment manufacturing industry improve quality and efficiency, and create more benchmark examples of intelligent manufacturing.