KUKA Genius

KUKA established this special form of solid-state welding as an industrial joining process more than 50 years ago. With the Genius, KUKA is now offering a compact and modular friction welding machine with up to 300 kN of forge force for the flexible implementation of friction welding processes for a broad product range.

The advantages of the KUKA Genius

Simple and ergonomic operator control

The result of the new development is a machine with improved access, light doors and a large working area. Operator control is carried out intuitively via a touch panel with a modern graphical user interface.
Maximum accuracy

The KUKA Genius achieves extraordinarily high precision and welding quality thanks to precise bearing technologies, pre-tensioned roller guides and a stress-optimized machine bed.
Custom-tailored complete solution

A sophisticated hydraulic system, diverse drive solutions in various performance classes and a very large speed/load range make the Genius a genuine all-rounder for covering a wide spectrum of components.
Ease of servicing and minimal maintenance

The KUKA Genius boasts robust components with a virtually wear-free direct drive and long lubrication intervals. Beyond this, generously dimensioned operator and maintenance doors enable optimal access.
Simple installation...

The KUKA Genius is a plug&play solution. Not requiring any external control cabinets, it can be installed quickly and relocated with minimal effort.
…in a minimum of space

With a footprint of just 12 m², the KUKA Genius is one of the most compact machines in its performance class and ensures optimal utilization of the available floor space.
Industrie 4.0

An extensive array of sensors monitor the status of the machine and the entire welding process. The data can be transmitted to the cloud for evaluation via standardized interfaces, thereby enhancing productivity and data transparency.
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KUKA Genius in detail

Optimal access

Easy access - Generously dimensioned operator and maintenance doors enable optimal access from above and at the front of the machine.
Integrated light curtain

Short cycle times and utmost safety - Integrated light curtain for cycle time optimization with the highest safety level
User-friendly operator panel

Touch screen operation with clearly structured menu navigation makes it quick and intuitive to learn how to operate the Genius. A digital operating manual with search function and maintenance schedule further increases user friendliness.
Flexible swarf conveyor

Thanks to the optimized design, equipment for swarf removal can now, for the first time, be optionally positioned at the side or rear of the machine.
Transport-friendly design

Plug & play - Integration of hydraulic and electrical equipment reduces the floor space requirement and simplifies transportation and installation.
Working area

Improved ergonomics and a readily accessible working area for convenient loading and retooling. The easy-to-clean interior enclosure protects cables and piping from dirt and damage.

With the KUKA Genius, it is possible to configure a large number of technology modules with customers according to their requirements – precisely as necessary for the component, production planning and manufacturing strategies of the future user.

Michael Büchler, project manager in the field of mechanical construction

Development of the KUKA Genius friction welding machine

An interdisciplinary project team of more than 40 specialists from all fields worked on developing the new generation of friction welding machines. The challenge: to create a product meeting the requirements of customers while being straightforward and not overly complex. KUKA has achieved this with the KUKA Genius. The customized comprehensive solution is easily installed, space-saving and can be configured according to the welding task.

Winner of multiple awards

Red Dot Design Award

The compact and modular Genius friction welding machine from KUKA won the 2015 Red Dot Design Award in the Product Design category. Up against thousands of other entries, the KUKA Genius came out on top due to its appealing design coupled with a high degree of functionality as well as straightforward and ergonomic operation.

German Design Award Special 2016

In the “Excellent Product Design” category, KUKA also received the German Design Award Special 2016 for the Genius. This award recognizes particularly innovative products and projects as well as manufacturers in the international design sector.

Industrie 4.0 Innovation Award

In 2017, the jury from VDE Verlag and the German Electrical and Electronic Manufacturers’ Association (ZVEI) honored KUKA SmartConnect.frictionwelding with the Industrie 4.0 Innovation Award.

Among other things, the cloud application facilitates horizontal and vertical integration, ensures resource efficiency and conforms to the reference architecture for Industrie 4.0 (RAMI 4.0).

Our intuitive user interface stands out through the

Welding process

User-friendly configuration and setting of the welding process

Data backup

Input and backup of data via USB interface

Documentation

Documentation of the welding results by means of database, printer or PDF export

Parameter profiles

Graphical representation of current and archived parameter profiles

Control & monitoring

Control and monitoring of all parameters of the welding process in the millisecond range

Quality management

Full traceability via data matrix code. Weld data are assigned to the individual components.

Program management

Management of up to 1,000 welding programs

Presentation of values and status

Display of the actual values and parameters as well as the current status in plain text

Equipment packages

• Automatic length adjustment (via adjustable backstop)
• Double-slide system with two center clamps for long components
• Defined-angle positioning of the components
• Automatic compensation of length tolerances (via active travel control)
• Virtual inertia welding
• Cycle time reduction by means of light curtain and automatic doors
• Steady rest & swarf conveyor
• Tool changer for flash removal
• Intelligent user administration with identification chip (EKS)

KUKA Genius type variants

Depending on your requirements and the range of products to be manufactured, KUKA supplies the KUKA Genius friction welding machine in the following type variants:

KUKA Genius eco®

The basic entry-level model for simple welding tasks.
KUKA Genius plus®

The mid-range model with automatic backstop adjustment for even greater productivity.
KUKA Genius power®

The fully equipped variant with a high-performance drive for the most challenging material combinations and angle positioning.