Robotic Welding: How It Works & When It Makes Sense

Automation and robotics are increasingly prevalent across manufacturing, including welding and fabrication. With proper implementation, robotic welding cells can significantly increase efficiency and productivity.

However, not all work suits robotic welding. In this article, we’ll discuss how robotic welding works and what key factors you need to consider before investing in it.

What Is Robotic Welding and How Does It Work?

Robotic welding uses a computer-controlled robotic device to perform production welds on parts. Often these resemble the robot arms seen in car manufacturing but can also be more linear or static, with the part moving rather than the torch.

In most cases, a robot will be programmed to make specific welds in a repetitive manner. Robot welders are often accompanied by manipulators that can rotate and position the part before or even during welding to put joints in the perfect position for welding.

The robots themselves commonly use multiple joints with servo motors and high-precision gearboxes to enable motion. These motors can position the arms with incredible accuracy, which is needed to ensure the welds made are correctly placed.

Types of Robotic Welding Systems Used in Manufacturing

Robot arms are not the only way to automatic welding; there are numerous other forms a robotic welding cell can take:

• Linear: an automated welding head on an in-line track, often used for long straight seams, where 3-dimensional control is not needed, often set up as semi-robotic welders
• Rotary: With more simple joints, such as pipe flange connections or similar, the part can be rotated whilst the torch remains stationary
• Cartesian: An X-Y robot that typically has motors on all 3 axes but with limited up and down (Z) travel or control
• Cobot arms: Using a smaller arm, often with a reach of a typical workbench, these are designed to work alongside an operator for repetitive welding tasks
• Robotic arms: these are the most functional but the most expensive welding robots; a multi-jointed arm, these are available with anything from a 1 metre to 5m+ reach

Benefits of Robotic Welding: Speed, Precision, and Consistency

The benefits of robotic welding machinery are numerous, especially as the robots and their control systems get better and workplace laws become stricter.

• Downtime: an automated welding cell can run 24/7. Coupled with simple but effective workholding and feeding systems, one person can run multiple welding robots at a time
• Consistency: whilst only the very best robots and control systems can rival a highly skilled welder, one benefit is consistency; a welding robot will produce the same quality job regardless of all external factors
• Precision: With the right sensing and control systems, welding robots can produce highly accurate welds
• Safety: One of the highest costs and limitations of welding in modern workplaces is managing workers’ safety. If the operator can be removed from the welding environment – during welding at least – the risks are far lower.

Limitations of Robotic Welding for Custom or Low-Volume Jobs

Robotic welding only really makes sense on large batches of parts. For small runs or custom jobs, the time needed to program the robot and design and manufacture jigs makes using an automated setup uneconomical.

Other limitations of robotic welding include:

• High startup costs: robots are expensive, as are the tooling, software, and personnel needed to install and maintain them, meaning they have a high barrier to entry
• Adaptability: if a part’s design or specification changes, the robot’s program needs to be adapted and tested before it can go back into production
• Size and shape constraints: despite modern welding robots being available in all shapes and sizes, there are still parts that cannot be made efficiently using the technology

When Robotic Welding Makes Sense for Your Business

Investing in robotic welding can be expensive, costing anything from $50,000 to $500,000+, depending on the complexity and capability of the setup. It’s important to formulate a sound business plan before proceeding.

To make robotic welding cost-effective and provide an adequate ROI, contracts for large quantity orders need to be secured in advance.

The exact point at which a machine will break even, or the minimum amount of billable time per month required to turn a profit, will depend on the type of work and overheads your business faces.

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