{"id":16588,"date":"2026-03-06T09:44:55","date_gmt":"2026-03-06T09:44:55","guid":{"rendered":"https:\/\/lipro.pro\/unkategorisiert\/comparison-of-modular-systems-and-welded-structures-in-industrial-automation"},"modified":"2026-11-05T12:20:49","modified_gmt":"2026-11-05T12:20:49","slug":"comparison-of-modular-systems-and-welded-structures-in-industrial-automation","status":"publish","type":"post","link":"https:\/\/lipro.pro\/de\/fachartikel\/comparison-of-modular-systems-and-welded-structures-in-industrial-automation","title":{"rendered":"Comparison of Modular Systems and Welded Structures in Industrial Automation"},"content":{"rendered":"\n<h1><\/h1>\n&nbsp;\n<h2>1 . Introduction<\/h2>\n&nbsp;\n\nIn industrial automation, the selection of a structural system represents one of the key technical and economic decisions in the design of production lines, conveyor systems, workstations, and safety guards.\n\nInvestors and engineers most commonly choose between two basic approaches:\n<ul>\n \t<li>conventional welded steel structures,<\/li>\n \t<li>modular systems based on aluminum profiles.<\/li>\n<\/ul>\nBoth approaches are technically justified and widely used; however, they differ significantly in terms of load capacity, flexibility, implementation speed, upgrade possibilities, and life-cycle costs.\n\n&nbsp;\n<h2>2. Structural Concepts<\/h2>\n&nbsp;\n<h3>2.1 Welded Structures<\/h3>\n&nbsp;\n\nWelded structures are based on steel profiles, sheet metal, and tubular elements that are permanently joined by welding. After welding is completed, surface treatment follows (powder coating, painting, or galvanizing) to provide corrosion protection and an aesthetically finished appearance.\n\nSuch structures are particularly suitable for applications involving high static and dynamic loads, as well as in cases where structural requirements are long-term stable and unlikely to change.\n\n&nbsp;\n<h3>2.2 Modular Aluminum Profile Systems<\/h3>\n&nbsp;\n\nModular systems are based on standardized aluminum profiles with slots, connection elements, and system accessories. The structure is assembled mechanically, without welding, enabling fast assembly, disassembly, and adjustments.\n\nModern modular systems cover a wide range of applications \u2014 from ergonomic workstations to load-bearing structures of conveyor and automated lines. The key advantage lies in the system-based design, which allows the combination of standard elements and optimization of the structure according to project requirements.\n\nIn practice, various profile series are used (e.g., 30, 40, 45, 60, 80 mm and above), allowing proper adaptation to the mechanical demands of each application. Compatibility with established industrial standards also plays an important role, as it enables greater component integration.\n\nIn development-oriented companies, modular systems are often enhanced with proprietary solutions. For example, Lipro has developed its own modular profile and component system\nthat maintains compatibility with established systems (e.g., Bosch Rexroth type), while allowing optimization according to specific project requirements. An additional advantage of this approach is the continuous availability of key profiles and components from stock, which further shortens delivery times and increases project responsiveness.\n\nThis combination of standardization and in-house development enables technical flexibility without being limited to a single system.\n\n&nbsp;\n<h2>3. Mechanical Properties and Dimensioning<\/h2>\n&nbsp;\n<h3>3.1 Load Capacity and Rigidity<\/h3>\n&nbsp;\n\nWelded structures generally achieve higher absolute rigidity, especially over large spans and under concentrated loads. Due to continuous welded joints, they are less sensitive to local deformations.\n\nIn modular systems, load capacity directly depends on:\n<ul>\n \t<li>the selected profile cross-section,<\/li>\n \t<li>span length,<\/li>\n \t<li>load distribution,<\/li>\n \t<li>type and quality of connection elements.<\/li>\n<\/ul>\n&nbsp;\n\nA properly dimensioned modular structure can meet most requirements in industrial automation. However, it requires a precise engineering approach and thorough knowledge of the mechanical characteristics of individual profiles and joints.\n\nIn practice, a combination of different profiles is often used to optimize weight, cost, and rigidity.\n\n&nbsp;\n<h2>4. Flexibility and Adaptability<\/h2>\n&nbsp;\n<h3>4.1 Changes During the Project Phase<\/h3>\n&nbsp;\n\nIn welded structures, any modification after fabrication requires cutting, re-welding, and renewed surface treatment. This increases costs and extends lead times.\n\nModular systems allow:\n<ul>\n \t<li>quick dimensional adjustments,<\/li>\n \t<li>addition or removal of modules,<\/li>\n<\/ul>\neasy modifications without interfering with the entire structure.\nIn automation projects, where requirements often change during development or installation, this flexibility is extremely important.\n\n&nbsp;\n<h3>4.2 Upgrades and Production Reorganization<\/h3>\n&nbsp;\n\nModern production lines adapt to new products, cycle time changes, and logistical requirements.\n\nModular systems allow:\n<ul>\n \t<li>later expansions,<\/li>\n \t<li>relocation or reorganization of equipment,<\/li>\n \t<li>reuse of components.<\/li>\n<\/ul>\nThe structure thus becomes a flexible platform rather than a one-time, static solution.\n\n&nbsp;\n<h2>5. Manufacturing and Assembly Time<\/h2>\n&nbsp;\n\nIn modular systems, the availability of standard profiles, connectors, and accessories plays a crucial role. If key components are continuously available from stock, delivery times can be significantly shortened and the risk of project delays reduced.\n\nIn automation projects, where deadlines are often tight and requirements may change even during execution, this aspect represents an important competitive advantage.\n\n&nbsp;\n\n&nbsp;\n<h2>6. Economics Throughout the Life Cycle<\/h2>\n&nbsp;\n<h3>6.1 Investment Cost<\/h3>\n&nbsp;\n\nWelded structures can be more cost-effective in very simple and static applications. Modular systems may have higher initial material costs due to high-quality profiles and system components.\n\nIt is important to emphasize that steel as a raw material is generally cheaper than aluminum; however, the base material cost does not represent the total cost of the structure. In welded steel structures, additional technological phases must be considered, such as cutting, welding, possible stress-relief annealing, machining, weld grinding, and mandatory surface protection (painting, powder coating, or galvanizing).\n\nThese operations increase labor costs, extend manufacturing time, and require additional logistics and quality control.\n\nIn practice, it often turns out that the final price of a welded structure \u2014 despite the lower cost of steel as a material \u2014 can ultimately be higher than a modular aluminum solution due to all associated processing steps and longer production time.\n\nTherefore, any realistic comparison must consider the entire production process and not only the cost of the base material.\n\n&nbsp;\n<h3>6.2 Total Cost of Ownership<\/h3>\n&nbsp;\n\nA long-term analysis must consider:\n<ul>\n \t<li>costs of modifications and upgrades,<\/li>\n \t<li>production downtime costs,<\/li>\n \t<li>possibility of material reuse.<\/li>\n<\/ul>\n&nbsp;\n\nModular systems often demonstrate a lower total cost of ownership, as they allow rapid adjustments without major interventions and enable component reuse in new projects.\n\n&nbsp;\n<h2>7. Safety, Ergonomics, and Standardization<\/h2>\n&nbsp;\n\nModular systems allow easy integration of safety fences, doors, protective elements, and ergonomic workstation adjustments.\n\nThe use of systems compatible with established industrial standards is particularly important.\n\n&nbsp;\n\nThis enables:\n<ul>\n \t<li>use of a wide range of additional equipment,<\/li>\n \t<li>long-term component availability,<\/li>\n \t<li>easy integration of external systems.<\/li>\n<\/ul>\n&nbsp;\n\nAt the same time, the development of proprietary modular solutions allows optimization of the structure according to actual project needs \u2014 whether in terms of load capacity, weight, cost, or specific technical requirements.\n\nThis approach combines the advantages of standardization and engineering flexibility, which is essential in modern automation.\n\n&nbsp;\n<h2>8. Conclusion<\/h2>\n&nbsp;\n\nThe choice between modular systems and welded structures is not a question of absolute superiority of one approach over the other, but rather of suitability for a specific application.\n\nIn modern industrial automation, where flexibility, implementation speed, and long-term adaptability are key competitive factors, modular systems represent a technically mature and economically efficient solution.\n\nThe combination of standardized systems, compatibility with established industrial solutions, and in-house development of profiles and structural elements enables companies to achieve greater technical independence, faster project execution, and long-term optimization of production systems.\n","protected":false},"excerpt":{"rendered":"<p>&nbsp; 1 . Introduction &nbsp; In industrial automation, the selection of a structural system represents one of the key technical and economic decisions in the design of production lines, conveyor systems, workstations, and safety guards. Investors and engineers most commonly choose between two basic approaches: conventional welded steel structures, modular systems based on aluminum profiles. [&hellip;]<\/p>\n","protected":false},"author":3,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[84],"tags":[],"class_list":["post-16588","post","type-post","status-publish","format-standard","hentry","category-fachartikel"],"acf":[],"_links":{"self":[{"href":"https:\/\/lipro.pro\/de\/wp-json\/wp\/v2\/posts\/16588","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/lipro.pro\/de\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/lipro.pro\/de\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/lipro.pro\/de\/wp-json\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"https:\/\/lipro.pro\/de\/wp-json\/wp\/v2\/comments?post=16588"}],"version-history":[{"count":2,"href":"https:\/\/lipro.pro\/de\/wp-json\/wp\/v2\/posts\/16588\/revisions"}],"predecessor-version":[{"id":16829,"href":"https:\/\/lipro.pro\/de\/wp-json\/wp\/v2\/posts\/16588\/revisions\/16829"}],"wp:attachment":[{"href":"https:\/\/lipro.pro\/de\/wp-json\/wp\/v2\/media?parent=16588"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/lipro.pro\/de\/wp-json\/wp\/v2\/categories?post=16588"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/lipro.pro\/de\/wp-json\/wp\/v2\/tags?post=16588"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}