Industry

Welding automation / Steel fabrication

Country

Germany

Software

Siemens TIA Portal · S7-1200 · Fronius WeldCube · PROFIBUS

Duration

3 weeks

Welding station replatform — Fronius WeldCube integration and seam traceability

The situation

A welding automation OEM was running an automated welding station on an S7-200 controller that was no longer supported. The client had recently acquired a new Fronius welding source with PROFIBUS capability, which they wanted to use to implement per-seam weld data logging for customer traceability requirements. The existing hardware could not support this — the station required a full control system replatform alongside the Fronius integration.

What GFE did

GFE replatformed the welding station onto a Siemens S7-1200 in TIA Portal, integrating the Fronius welding source via PROFIBUS and implementing per-seam weld data logging with automatic export to Fronius WeldCube. From the first production day after commissioning, every weld seam had a complete data record — parameters, timestamps, and deviation flags — exportable for customer audit. The full project from briefing to commissioned system was completed in three weeks.

Results

S7-1200

replatformed from S7-200

WeldCube

integrated via PROFIBUS

100% seams

logged and traceable

3 weeks

brief to commissioned

We finally have weld data our customers can audit. That was a commercial requirement we couldn’t meet before.

Why GFE for PLC programming

Each project is staffed with engineers experienced on the relevant platform — TIA Portal, TwinCAT, Pilz, or Rockwell.

Practical experience with EN ISO 13849, SISTEMA calculations, and SRP/CS documentation for CE marking and TÜV review.

Support can be engaged for a single project or structured as a long-term team extension — without permanent hiring.

All team members are fluent in English, with additional language skills in German, Italian, Spanish, and more.

Have a PLC migration, new machine, or safety certification project?

Discover our case studies

Contact us

Tell us about your project

Head office

30, Estrady, Warsaw, Poland 01-932

Phone: +48 798 763 604

For general enquiries: info@gfe-solutions.com

For sales enquiries: inquiry@gfe-solutions.com

Back office

201/203, Kharkivske shose,Kyiv, Ukraine 02121

Email: info@gfe-solutions.com

Phone: +38 098 237 0047

Our customers

Our company produces safety-relevant welding assemblies for the chemical and pharmaceutical industry.

Due to the fact that it has become increasingly difficult to find good engineers and designers for our design department at our location in rural Münsterland, we set out at the end of 2018 to look for new external solutions in the service market.

 

Christian Menke

CEO V. KRANZ GmbH, Dülmen

I really appreciate GFE’s flexibility and openness for new challenges. They are not afraid to start a new journey.
If I think about the external circumstances of the project we started together, we reached a learning curve and relating results that I did personally not expect.

Daniel Ilge

Head of Technology & Product Management at WALDRICH COBURG GmbH

We required additional capacity and professional support for our R&D Team especially for a new product development.

And GFE Solutions offers capable support by very well-educated engineers. High professionalism. On time delivery and great communication (native German speakers).

Frank Pfister

CEO of CVS engineering GmbH

We are the company in constant need for plants for research or pilot projects of our clients. Last year we were working over the order in the field of medical technologies, which we succeeded to realize, including thanks to efforts of GFE Solutions team.

Dr. Thomas Bauer

Chief operating officer and member of the Board of DIENES Apparatebau GmbH

We were in need of help with our design department ressources and we had to move fast, internal ressources were not available and GFE was able to help quickly and competent. GFE works with dedication to the very needs of its customers, has a variety of specialists and has offered a fair price on a transparent basis.

Sebastian Schuelke

Managing Director at SICON GmbH

We were looking for additional engineers to expand our construction capacity. You seemed to be a young, motivated Team and except your professional expertise, your personal commitment made me confident to work with you. The cooperation has been seamless and very productive from the start. We are happy with the results.

Lukas Jochimek

Technical Manager at Schauenburg Maschinen- und Anlagen-Bau GmbH

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