Conceptual design and virtual prototyping of an adaptive clamping system for an automatic steel-profile welding machine

Current manufacturing trends emphasize the development of production systems characterized by high flexibility, adaptability, and responsiveness to dynamic market conditions. At the same time, reducing energy consumption, optimizing resource use, and minimizing waste, especially time, have become strategic priorities, requiring a fundamental rethinking of both design and operational paradigms. Graf Industries S.p.A., a company specializing in automated machinery for the production of Polyvinyl Chloride (PVC) window frames, continuously innovates to improve efficiency and process sustainability. In some of its production lines, however, operator intervention is still required during setup and changeover phases, which represent major sources of inefficiency and downtime. To address this limitation, the company initiated the full automation of the clamping unit of its automatic resistance welding machine for steel profiles. In this context, the present thesis work reports on the conceptual and embodiment design of an adaptive clamping system intended to replace the existing module of an automatic resistance welding machine for steel profiles. The redesign was driven by the need to improve the system’s adaptability to different profile geometries and dimensions, reducing setup time and eliminating manual intervention. A review of existing industrial adaptive clamping technologies was carried out to identify the most effective principles and to guide the development of a novel conceptual design integrating the best features of current solutions with innovative elements tailored to the machine’s operating constraints. The design process involved defining the functional requirements and boundary conditions, selecting suitable commercial components from industrial catalogues, and integrating newly developed custom parts specifically conceived for this application. A 3D virtual prototype of the system was defined in SolidWorks, using modern 3D Computer Aided Design and Engineering tools to assess its mechanical behavior and validate the structural integrity of the assembly. The embodiment design phase concluded with the generation of detailed 2D manufacturing drawings, enabling the production of the first laboratory-scale prototype. The prototype, realized through a combination of machined and additively manufactured components, was experimentally tested to evaluate its performance and functional reliability. The results confirmed the feasibility of the adaptive concept and its potential for future development, including the integration of actuation and control electronics for full-scale welding trials.