At the Production Center in Jaworzno, at the beginning of January 2026, the process of implementing a new robotic workstation into production was completed. Designed as a 7‑axis welding portal intended for welding large‑scale structures made of high‑strength steels (grades S690QL and S960QL) using method 135 (MAG), the system consists of a suspended K6‑type robotic arm manufactured by IGM, equipped with a Fronius TPSi welding power source and an additional hardware application in the form of a supplementary torch for preheating the steel prior to welding. This is a fully developed and implemented concept created by a team of welding engineers and technology specialists from ZRE Katowice S.A.

The robotic welding portal is equipped with a range of functions that ensure an optimal and repeatable robotic welding process using the MIG/MAG method. The installation consists of two independent workstations:

• the first is equipped with an L‑type manipulator with a load capacity of 10 tons,
• the second is equipped with a positioner with a load capacity of up to 14 tons, enabling rotation of the mounted component around one axis.

The welding process itself, thanks to the use of the Fronius TPSi welding power source, is carried out using modern synergic welding lines such as Pulse and PMC, which significantly improves welding arc stability, provides better control of linear heat input, and minimizes weld spatter.

Thanks to the implementation of robotic welding, the following results have been achieved:

• increased welding process efficiency (the possibility of operating 24 hours a day, 7 days a week, without interruptions, on two independent positioners),
• repeatable welding quality combined with the required preheating of the components prior to welding,
• reduction of errors during the welding process (including a significant improvement in weld joint quality due to stable arc guidance and repeatable current‑voltage parameters),
• the ability to perform quick changeovers and flexibility in robotizing two different components,
• correction of inaccuracies in components prepared for welding,
• the possibility of involving a machine operator in the process (operator training takes considerably less time than welder training),
• ensuring occupational safety and reducing health hazards for employees (the process is carried out in a separated cell equipped with appropriate ventilation),
• optimization of operating costs (including reduced consumption of welding materials and electrical energy resulting from a repeatable process using modern synergic welding lines).

The workstation was supplied by IGM Robotersysteme AG, while assembly was carried out by Supra Elco sp. z o.o. We would like to thank both companies for their professional cooperation and efficient project execution.

We also extend our thanks to all employees and team ZRE Katowice Production Center in Jaworzno involved in the investment process.