Rekers worked with WeCobot and Kemppi to implement a collaborative welding solution using a Universal Robots cobot, Kemppi X5 FastMig Pulse, and GXe-C torch. The system improves weld quality, reduces welders’ strain, and increases production flexibility.

Rekers: A legacy of heavy-duty machinery

Founded in 1955, Rekers GmbH designs and manufactures heavy-duty machinery for stone and concrete block production. The company’s portfolio includes complex steel frames, lifting systems, and handling equipment that all require high-quality welded structures built to last. With decades of expertise, Rekers is known for robust, precise, and durable equipment serving customers worldwide.

To further enhance welding quality and relieve employees from physically demanding tasks, Rekers decided to explore collaborative automation. Working with integrator WeCobot, and supported by Kemppi and local dealer Wocken Industriepartner, they implemented a modern cobot welding system that now supports the production of welded components in their daily operations.

Cobot welding challenge: better quality and less strain

Before introducing the cobot, Rekers faced challenges in maintaining consistent welding quality and easing the strain on skilled welders. The initial acceptance of new technology among employees was hesitant, but witnessing successful demonstrations and testing of welded parts built confidence.

Rekers also wanted to maintain the trusted welding standards they had established with Kemppi equipment. Since Kemppi machines were already part of their standard setup through Wocken Industriepartner, the combination of a Universal Robots cobot and the Kemppi X5 FastMig Pulse offered a reliable and familiar foundation for welding automation.

Cobot welding efficiency with Kemppi X5 FastMig Pulse and WeCobot

The final solution combines a Universal Robots cobot with the Kemppi X5 FastMig Pulse and the GXe-C cobot torch, forming a powerful and flexible setup for automated welding. The X5 FastMig Pulse, Kemppi’s top industrial model, offers a high duty cycle, seamless automation compatibility, and stable performance for long welds. It's a perfect fit for Rekers’ heavy steel components, such as machine frames and lifting systems.

Advanced Kemppi features, such as MAX Cool, MAX Speed, and WiseFusion, ensure excellent penetration, reduced heat input, and smooth, consistent seams. Functions such as Seam Tracking and Touch Sensing allow the cobot to follow complex weld joints and perform multilayer welding automatically, which is crucial for Rekers’ thick and high-strength structures.

The remote control panel further improves efficiency. Because the cobot operates on two large welding tables mounted on a track, being able to fine-tune parameters directly at the workpiece saves time and simplifies operation for welders.

A key part of the success was WeCobot’s proprietary software, designed by welders for welders. Its modular structure covers all main welding processes, making programming fast and intuitive. Operators can easily define weld seams, select stored multilayer sequences, and even adjust torch angles or movement type (push or drag) without reprogramming. This flexibility was especially valuable at Rekers, where many components require layered, precise welds.

WeCobot’s ONE Ring function enables programming with a single button, drastically reducing setup time. “Our software and hands-on approach make cobot welding intuitive and fast for welders. They can program complex seams easily, achieving high-quality results from day one”, says Tijmen Horstman, Marketeer, WeCobot.

Collaboration between Rekers, WeCobot, Kemppi, and dealer Wocken Industriepartner worked seamlessly. Wocken provided expert welding guidance, and the strong cooperation among all partners allowed for quick system delivery, installation, and certification. The result is a reliable and user-friendly cobot welding cell that consistently delivers high-quality results every day. Rekers now plans to extend its use to additional assemblies across production.