Welding is an essential process in manufacturing and construction. Many people think that welding is a difficult process, but with the right training, anyone can learn how to weld. In this blog post, we will discuss the basics of robotic welding. We will also provide tips for welders who are looking to transition to using a robot welder. Stay tuned!
What is robotic welding?
Robotic welding, also known as automated welding, is the automated method of welding and handling a part utilizing mechanized programmable equipment. This relatively new use of robotics has successfully taken over a substantial number of welding tasks in the North American industry, filling the void created by the rising shortage of welding personnel.
The history of robotic welding is linked to the development of industrial robots in general, which dates back to the mid-twentieth century. Throughout the 1990s, processes improved, with electronic controls increasing to the point where numerous robots could be operated and coordinated at the same time. Operator interfaces have also been improved, and robot designs have been simplified and streamlined to allow for easier maintenance and repair.
To this day, technological improvements continue to increase the usefulness of industrial robots, with only the price of equipment and research standing in the way.
A robot welding unit is made up of many components that work together to weld pieces. These components include those actively involved in welding, as well as accessories and safety features to ensure the cell’s flawless operation.
What are robotic welding techniques and equipment?
Welding, robotics, sensor technologies, control systems, and artificial intelligence are all used in robotic welding. The components comprise software with specialized programming, welding equipment that delivers energy from the welding power source to the workpiece, and the robot that uses the equipment to perform the welding.
The process sensors of the robot measure the characteristics of the welding process, while the geometrical sensors detect the geometrical parameters of the welds. The control system modifies the output of the robotized welding process based on the welding procedure parameters established in the program by receiving and analyzing the input information from the sensors.
The main focus of robotic welding is on software and proper programming. The biggest costs are the equipment, testing, and operator training, which is why robotizing the welding process usually necessitates meticulous planning. The existing welding production, including all operations and expenses, must be investigated. Furthermore, the equipment’s compatibility with robotics must be investigated.
What are the applications of robotic welding?
Robotic welding has grown essential in metal and heavy industries, particularly in the automotive industry, which uses spot and laser welding, due to its time-saving benefits and high productivity.
It is ideally suited for brief welds with curved surfaces and repetitive, predictable operations that do not require continuous welding shifts and adjustments. The robot is also appropriate for long welds, such as in the shipbuilding industry, thanks to the use of external axes.
Although robotic welding is most commonly employed in mass production, where efficiency and quantity are critical, programs may be tailored to meet any requirements, and robots can be used for smaller and even one-off manufacturing while being cost-effective.
What are the advantages of robotic welding?
- Increased production – Robotic welding systems work swiftly and efficiently, making fewer mistakes than their human counterparts while greatly boosting production speed. Furthermore, unlike human workers, robots can work 24 hours a day, seven days a week.
- Enhanced quality and consistency – The automated technology produces repeatable weldments with extraordinary precision, repeatedly placing the same high-quality welds in the same location without fatigue. These methods’ precision also eliminates spattering, resulting in neater seams.
- Reduced energy – Automated welding systems save energy by running continuously, eliminating the need for costly start-ups. Furthermore, robots do not overwhelm, reducing the requirement for corrective welding and thereby reducing energy consumption.
- Decreased scrap – Every action made by a welding robot is planned and automated, reducing errors and, as a result, the quantity of scrapped pieces. This can be a critical component in remaining within budget for higher-value assignments.
Robotic welding offers many benefits for businesses. It is accurate, consistent, and fast. If you are looking to add this technology to your business, or want more information about it, please contact us. We would be happy to discuss with you this topic and answer any questions you may have.