Is robot welding a game-changer?

The world has come a long way to embracing robots as part of the workforce in many industries. For example, the automation industry was the first to embrace the use of robots which mostly worked alongside human workers. The welding process is now also automated, thanks to robot welding.

Robots are flexible, can also be programmed with ease, and require less hard tooling. Welding automation has increased accuracy, reduced a project’s turn-around time, and enhanced safety. These are some of the benefits that have made robotic welding a popular welding mode.

Moreover, welding robots have made the workplace safe for human workers. This is because they have been assigned all the dangerous jobs thanks to their high accuracy levels. Having robotic welding means that your production will improve quality no matter the size of the order and at affordable prices.

How accurate are welding robots?

When there’s proper training, planning and programming. Welding robot integration gives out immediate benefits. The reason is, you’ll have eliminated welding issues such as:

Slag entrapment
Inconsistent welds
Excessive undercut
No weld fusion
Excessive burn through

How does it work?

When robots are used in any process, they do require amending. That way, they will be able to accommodate automation. This is also true for welding robots, as they use several different tools that you will not necessarily find in their manual.

A welding robot comes with an arm that can move in different directions. For example, rectilinear types can move in three different dimensions. These robots also come with wide fillers, which help deliver filler wired to the robot. It will send as much filler wire as needed for a particular welding job.

The arm’s end is also a highly-heated torch that melts the metal, thereby enabling the welding process. Considering that the temperature can reach hundreds of thousands of degrees, the best way to go about welding is by using a robot. That way, work-related accidents are reduced because robots have a 99.9% accuracy level.

When a welding robot is working, a certified human worker will still have to stay close to it. The operator is the one who programs the controller. The operator does this with the help of a teach pendant. This pendant will move that arm, set programs and change the processes’ parameters.

Advantages of a welding robot over a human welder

High quality: Automation of process controllers has led to high-quality welding. Human error is also reduced, and human workers no longer have to deal with excess fatigue leading to poor welding results.
Welding consistency: Automation of the welding process has ensured high adherence to weld procedures. This, in turn, resulted in high-standard assurance preventing rework.
Greater output: Using a welding robot increases output. This is because human working hours, project concentration and endurance aren’t depended upon.
Labour cost reduction: Welding robots have the ability to perform the same tasks for long periods with minimum intervention from humans. Moreover, you won’t have to incur labour costs resulting from staff turnover, sick leave, overtime or injury.
Improved safety. As earlier mentioned, the welding process involves hot molten, and when this is coupled with human error, it could spell doom to your plant. Manual robots are used with their exceptionally high accuracy rate to prevent this.
Round-the-clock operation: Robots do not need rest as opposed to human welders. This means that you can work 24-hours a day. The possible result is an increased ROI brought about by customer satisfaction.
Consumable cost is reduced: When welding is automated, there is less waste owing to the robots high accuracy levels.

Disadvantages

However, just as it is with everything, welding robots also come with their disadvantages. They include:

The use of sophisticated welding machinery brings about high labour costs.
Lack of flexibility: Welding robots are primarily suitable in industries that have significant repetitive processes. Those companies having projects with limited scope may find it impractical to use welding robots.

Processes of robotic welding

There are several different processes of welding. They include:

Arc welding: This is one of the most common types of welding. In arc welding, an electric arc is used to generate heat of up to 6,500°F. This heat melts the metal ad then the molten metal is used to joint to other joints. Once it solidifies and cools, a stable connection will have been made.
Resistance welding: This is mostly used in projects requiring affordable eat-treating. In resistance welding, electricity current melts metal. The molten pool then goes between 2 metal bases, joining them to each other.
Spot welding: There are materials that are resistant to electric currents, and this is where spot welding comes in handy. These materials are more commonly found in the automotive industry. In such situations, resistance welding variations are used to connect thin metal sheets to one spot.
TIG welding: If a welding application requires high precision levels, TIG welding will get the job done. In TIG welding, an electric arc passes between a metal base and a tungsten electrode.
Plasma welding: This is welding that offers a high degree of flexibility. This is because it enables operators to easily change the temperature and speed of gas that’s passing the nozzles.
Laser welding: This is most suitable for projects involving joining metal parts in large volumes. They include joining medical components or jewellery.
MIG welding: This is welding that utilizes high deposition levels. In MIG welding, a wire continuously moves to the welder’s tip getting liquefied. The liquefied metal drips to the base as it joins that base to another.

Even though many other welding processes are used in various industries nowadays, the ones listed above are the most common ones. Having a clear grasp of the mentioned processes will give you a great understanding of the welding robot landscape.

Conclusion

Successful implementation of a welding robot requires a deep understanding of all welding processes and demands automation experience. Once you have that, you will see that robotic welders will finish your work safely and quickly.