Analysis of rope drum fabrication in manual and robotic welding

Mechanical Engineering

Študent: Goran Rajnar

Goran Rajnar is a graduate of the Mechanical Engineering programme at Academia, College of Short-Cycle Higher Education. He successfully defended his thesis paper in May 2023.


Diploma paper Goran Rajnar

In my thesis I analyze and compare the technological process of manufacturing a rope drum between a classic manual (hand) welding process and a robotic welding process. The thesis is based on a real case study of the company BJB machine locksmithing, which due to an increase in the volume of orders, is faced with the dilemma of whether to continue the production of rope drums with the existing production process or to invest in the modernization of technological equipment, more specifically the robotic cell.

In the first part of the thesis, I present material joining techniques based on professional literature, with an emphasis on MIG/MAG welding. I describe the MIG/MAG welding process, the technological characteristics of the process, and the necessary equipment for MIG/MAG welding. I also present the advantages and disadvantages of this welding method.

In the practical part of the thesis, I describe the entire process of manufacturing a rope drum. Based on a practical example, I collected the necessary data, and presented and calculated the actual cost of manufacturing a rope drum in the analysis section.

The chapter is divided into the manual manufacturing process and the robotic manufacturing process of the rope drum. The analysis of manual welding and the analysis of the robotic welding method includes a description of individual activities and the duration of each step, which serve as the basis for calculating the normative times.

In the conclusion of the thesis, I compare the two manufacturing methods in terms of cost and quality. I calculated the savings and presented the cost values for both manufacturing methods using graphs.

As part of the Pearson set assignment theme, I described the area of safety which is a very important factor in the manufacturing process. Finally, I provide an answer to the hypotheses posed in the introduction and present my view on the financial feasibility of investing in a robotized manufacturing process.

The thesis offers valuable insights into the advantages and disadvantages of both studied production methods and provides important findings for companies facing similar technological challenges.


Diploma paper Goran Rajnar


Diploma paper Goran Rajnar

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