ESTUN S10-140 Pro Advanced 6-Axis Robot for Arc Welding Systems

　　ESTUN S10-140 Pro:High-Performance 6-Axis Robotic Solution for Arc Welding

　　The ESTUN S10-140 Pro is a heavy-duty collaborative robot engineered to revolutionize industrial welding and heavy material handling.Boasting a robust 10kg payload and an 

expansive 1400mm reach,this model provides the necessary workspace and strength for large-scale arc welding systems and palletizing tasks.

　　Equipped with a specialized welding software package and high-resolution torque sensors,the S10-140 Pro delivers the smooth,consistent motion required for high-quality

 weld beads.Its advanced control system enables seamless integration with professional welding power sources,making it a cornerstone for smart manufacturing in the automotive 

and metal fabrication sectors.

　　Detailed Technical Specifications

　　The S10-140 Pro combines the safety of a collaborative robot with the performance of a traditional industrial manipulator.The core technical parameters are:

　　Degrees of Freedom(DOF):6-Axis

　　Rated Payload:10 kg

　　Maximum Reach:1400 mm

　　Pose Repeatability:±0.03 mm

　　Maximum Tool Speed:2.8 m/s

　　Ingress Protection:IP54(Arm)/IP20(Cabinet)

　　Safety Standards:ISO 13849-1,ISO 10218-1

　　Communication:EtherCAT,Modbus TCP,I/O

　　Robot Weight:38 kg

　　Power Consumption:~500W(Typical)

　　Core Features and Engineering Advantages

　　The S10-140 Pro features a high-rigidity structure that minimizes mechanical deflection,which is critical for maintaining arc stability during long welding cycles.The 1400mm 

reach allows the robot to handle large workpieces,such as vehicle chassis and structural steel frames,without the need for additional linear tracks.

　　The"Pro"series is distinguished by its advanced trajectory tracking technology.By utilizing a 2ms control cycle and 20-bit encoders,the robot ensures that the welding torch

 follows the programmed seam with sub-millimeter precision,significantly reducing the need for post-weld grinding or rework.

　　Safety is managed through a multi-layered sensor system.The S10-140 Pro can operate in a"collaborative mode"where it slows down when humans are nearby,or a"high-speed

 mode"when the area is clear.This flexibility optimizes production throughput while strictly adhering to international safety protocols.

　　Primary Application Scenarios

　　In arc welding systems,the S10-140 Pro is used for MIG,TIG,and Laser welding.Its wide reach and 6-axis flexibility allow it to access complex joints and tight angles that are 

difficult for human welders,ensuring deep penetration and consistent weld quality throughout the entire assembly.

　　For heavy-duty assembly,the 10kg payload allows the robot to carry heavy pneumatic grippers and components simultaneously.It is frequently used in the appliance industry

 for assembling washing machine drums and refrigerator frames where both reach and strength are mandatory requirements.

　　The S10-140 Pro is also highly effective in palletizing and depalletizing small to medium-sized boxes.Its reach allows it to stack products onto standard pallets with high 

precision,while its collaborative features allow it to work in shared spaces with warehouse personnel without traditional safety fencing.

　　Installation and Operating Instructions

　　The S10-140 Pro should be mounted on a heavy-duty steel pedestal or a dedicated welding table.Given its 1400mm reach and 10kg payload,the mounting surface must be able

 to withstand the dynamic forces generated during high-speed directional changes to prevent any loss of accuracy.

　　Connect the welding power source to the control cabinet via the EtherCAT or digital interface.This allows the robot to control welding parameters such as current,voltage,and

 wire feed speed in real-time,synchronizing the arc start and stop perfectly with the robotic motion path.

　　During the teaching phase,use the manual guidance feature to lead the torch along the welding seam.For arc welding,it is essential to define the"work angle"and"travel angle"

of the torch accurately.The S10-140 Pro’s software includes dedicated welding templates to simplify this process.

　　Critical Safety and Maintenance Notes

　　When used in arc welding,the robot and its cables must be protected from sparks and weld spatter.Use a specialized heat-resistant robot jacket and ensure that the welding 

ground cable is correctly attached to the workpiece to prevent current from flowing through the robot's bearings.

　　Regularly check the wire feeder and contact tip of the welding torch.A clogged tip can cause increased friction and mechanical stress on the robot's fifth and sixth axes.Periodic

 cleaning of the robot's joints will ensure that the IP54 protection remains effective against fine metallic dust.

　　Always perform a"dry run"of any new welding program with the arc power turned off.This allows the operator to verify that the torch does not collide with the workpiece or 

fixtures and that the high-flex cables have enough slack to complete the full range of motion safely.

　　Frequently Asked Questions(FAQ)

　　How does the S10-140 Pro handle the electromagnetic interference of arc welding?

　　The S10-140 Pro is built with industrial-grade electromagnetic compatibility(EMC)shielding to protect its internal sensors and control electronics.This is essential in arc welding

 environments where high-frequency starts and high-current arcs can generate significant electrical noise.

　　All communication between the robot arm and the control cabinet is handled via shielded cables and differential signaling.This design ensures that the 20-bit encoder data

 remains accurate and that the robot does not experience"ghost"collisions or signal drops during the welding process.

　　We also recommend using a dedicated grounding system for the welding power source that is separate from the robot’s electrical ground.This prevents"ground loops"and 

ensures that the high welding currents do not pass through the sensitive joints or the main CPU of the robot.

　　Can the 1400mm reach be extended for even larger workpieces?

　　While the physical reach of the S10-140 Pro is fixed at 1400mm,its working envelope can be effectively expanded by mounting the robot on a linear track or a gantry system.

The ESTUN control cabinet supports EtherCAT,which can easily synchronize with external seventh-axis hardware.

　　By adding a linear track,the robot can move along a long assembly line,performing welds on a series of workpieces or a single very long part.The software automatically 

compensates for the base movement,maintaining the precision of the welding torch relative to the moving frame.

　　For applications requiring even more dexterity,the robot can be integrated with a 2-axis welding positioner.This allows the workpiece to be rotated and tilted while the robot is

 welding,ensuring that the weld pool is always in the optimal"flat"position for maximum strength.

　　What welding power sources are compatible with the S10-140 Pro?

　　The S10-140 Pro is designed with an open communication architecture,making it compatible with leading global welding brands such as Miller,Lincoln Electric,Fronius,and 

Kemppi.Most modern power sources can be linked via EtherCAT,Profinet,or standard Analog I/O.

　　When using a digital interface,the robot can access advanced welding functions like"pulsed arc"or"cold metal transfer."This deep integration allows the robot to adjust welding

 parameters on-the-fly based on the specific geometry of the joint it is currently processing.

　　ESTUN also offers pre-configured welding packages that include the torch,wire feeder,and interface cables.These"plug-and-play"kits reduce integration time and ensure that all

 components are perfectly matched for the high-speed motion capabilities of the S10-140 Pro.

　　Is the S10-140 Pro suitable for heavy-duty palletizing?

　　Yes,the 10kg payload and 1400mm reach make the S10-140 Pro an excellent choice for palletizing medium-sized goods.It can easily reach all corners of a standard Euro-pallet

 or US-pallet,stacking boxes to a significant height while maintaining high positional accuracy.

　　The robot’s collaborative features are a major advantage in palletizing,as it can work in open areas where forklifts or manual pickers are active.If the robot detects a person in

 its path,it can automatically reduce its speed or stop,preventing accidents in busy warehouse environments.

　　For palletizing tasks,the robot can be equipped with vacuum grippers or mechanical clamps.The built-in I/O on the robot's flange allows for direct control of the gripper,simplify

ing the wiring and reducing the risk of cable snagging during the high-rotation movements of the sixth axis.

　　How does the S10-140 Pro ensure safety without a safety cage?

　　The S10-140 Pro utilizes highly sensitive torque sensors in each of its six joints to monitor external forces.If the robot encounters an obstacle that exerts more force than the 

user-defined safety threshold,it will stop its motion within a few milliseconds to prevent injury.

　　The system also supports"Safety Zones"and"Virtual Walls"which can be programmed into the controller.These invisible barriers restrict the robot's movement to a specific area,

ensuring that the arm or the tool never enters zones where human operators are expected to be present.

　　For maximum safety in high-speed applications,the robot can be integrated with external laser scanners.These scanners create a safety perimeter;when someone enters 

the"warning zone,"the robot slows down,and if they enter the"hazard zone,"the robot comes to a complete halt.

　　What are the advantages of the 20-bit absolute encoders in this model?

　　The 20-bit absolute encoders provide over one million points of resolution per revolution of each joint.This extreme level of detail allows the control system to make very fine

 adjustments to the robot's position,resulting in the±0.03mm repeatability that the S10-140 Pro is known for.

　　Because the encoders are"absolute,"the robot always knows its exact position in 3D space,even after a power failure.There is no need to perform a"homing"sequence or move 

the robot to a calibration point every time the system is turned on,saving valuable production time.

　　These encoders also contribute to the smoothness of the motion.By providing high-frequency feedback to the motor drives,they eliminate the"cogging"or micro-stuttering 

found in lower-resolution robots,which is critical for maintaining a steady arc and a uniform weld bead.

　　How does the manual guidance feature assist in welding path setup?

　　Manual guidance,often called"Lead-Through Teaching,"allows the welding engineer to grab the robot arm and physically move the torch along the desired weld path.The 

robot’s sensors cancel out the weight of the arm,making it feel weightless and easy to maneuver.

　　This method is much more intuitive than using a joystick or teach pendant buttons to line up a torch on a complex curved seam.The operator can precisely position the torch,

set the tilt angle,and record the points with a single button press on the flange.

　　Once the path is recorded,the software can automatically smooth out the points to create a perfect trajectory.This feature significantly reduces the time required to set up new 

parts,making the S10-140 Pro highly cost-effective for small-batch and"high-mix"manufacturing.

　　Can the S10-140 Pro be used for TIG welding which requires high precision?

　　TIG welding(Tungsten Inert Gas)is one of the most demanding welding processes due to the extremely tight arc length required.The S10-140 Pro’s high repeatability and 

vibration-free motion make it one of the few collaborative robots capable of high-quality TIG applications.

　　The robot's control system can manage the complex TIG start sequence,including pre-flow gas,high-frequency arc start,and the gradual ramping of current.Its precise Z-axis 

control ensures that the tungsten electrode stays at a constant distance from the workpiece,preventing contamination.

　　For TIG applications,we recommend using the robot in its"High Precision"mode,which prioritizes trajectory accuracy over maximum speed.This ensures that the weld pool 

remains stable and that the heat-affected zone is minimized,resulting in aesthetically pleasing and structurally sound welds.

　　What kind of maintenance is required for the robot’s joints and reducers?

　　The S10-140 Pro is designed for long-term industrial use with minimal maintenance.The harmonic reducers used in the joints are lubricated for life under normal operating 

conditions.However,in high-duty cycle welding applications,a yearly inspection of the grease is recommended.

　　The main maintenance task is checking the integrity of the protective seals and the external cables.In welding environments,the cables are exposed to intense UV light and heat,

which can cause the outer jacket to become brittle over time.Replacing these cables before they fail prevents unexpected downtime.

　　We also recommend a periodic"backlash check"on the joints.By measuring the mechanical play in the arm every 5,000 hours of operation,you can monitor the wear on the 

reducers and plan for any necessary servicing well in advance of a potential failure.

　　What software tools are available for offline programming(OLP)?

　　The S10-140 Pro is compatible with several major offline programming software suites,including RoboGuide,Visual Components,and ESTUN’s own simulation tools.OLP allows 

engineers to create and test welding programs on a computer before transferring them to the robot.

　　This is particularly useful for complex assemblies where calculating collision-free paths manually would be too time-consuming.The software can simulate the entire welding 

cell,including the robot,the torch,the jigs,and the workpiece,ensuring a"first-time right"program.

　　Offline programming also allows for"Seam Tracking"simulation.You can use the software to determine the best mounting position for a laser seam tracker or a touch-sensing

 probe,ensuring that the robot can compensate for any variations in the physical parts during the actual welding process.