What are the Advantages of Robotic Welding? - dplaser

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Robot laser welding machine is a kind welding equipment in modern industrial production. Compared with traditional welding system, robotic laser welding machines have many advantages, such as high precision, high efficiency, environmental protection, energy saving and high reliability. This article will introduce you to the many advantages of the best robotic welding systems in industrial applications.

Part 1: What are the Advantages and Disadvantages of Robotic Welding

At present, the research of robotic laser welding technology mainly focuses on high power lasers, high beam quality, high energy density laser devices, high efficiency power supply and automatic control technology. Robotic welding systems can help manufacturers and businesses simplify operations, reduce costs and increase production efficiency. Robots can also be a good solution to the shortage of qualified welders

1.1 Advantages of Robotic Welding

Robotic welding offers increased productivity, improved weld quality, enhanced safety, cost savings, flexibility, and the ability to collect and analyze valuable data. These advantages make it an attractive option for many manufacturing industries.

Increased productivity

Robots can work continuously without the need for breaks, resulting in higher productivity and increased throughput. They can also perform repetitive tasks with high precision and speed, reducing cycle times and improving overall efficiency.

Consistency and quality

Robotic welding ensures consistent weld quality as it follows programmed instructions with high accuracy. The robots can maintain a stable arc, consistent heat, and precise weld placement, resulting in stronger and more reliable welds. This reduces the likelihood of defects and the need for rework or repairs.

Improved safety

By using robots for laser welding tasks, human operators are removed from hazardous environments that involve exposure to high temperatures, fumes, and potentially dangerous welding operations. This improves workplace safety and reduces the risk of accidents and injuries.

Cost savings

While there are initial investments involved in setting up a robotic welding system, it can lead to long-term cost savings. Robots can work faster and more efficiently than humans, reducing labor costs. The consistent quality also reduces material waste and rework expenses. Moreover, robots can operate continuously, maximizing production time, and increasing overall profitability.

Flexibility and versatility

Robotic welding systems can be programmed to handle various welding applications and adapt to different production requirements. They can switch between different parts or welding configurations quickly and easily, allowing for greater flexibility in manufacturing processes. This versatility enables manufacturers to respond quickly to changing market demands and product variations.

High Automation & Intelligent

Compared with traditional welding, the biggest advantage of robotic laser welding technology is automation. The automatic fiber laser welding robot can be connected with a computer or an on-site controller to realize automatic and semi-automatic control.

Many robotic welding systems are equipped with advanced sensors and monitoring capabilities that allow for data collection during the welding process. This data can be analyzed to identify trends, optimize welding parameters, and improve overall process control.

1.2 Disadvantages of Welding Robot

Complicated Setting

Before using the robot welding machine for welding, it is necessary to set and adjust the parameters of the robot welding machine according to the specific welding task, such as welding speed, welding current, welding time, welding distance, etc. If you need robotic welders to perform a variety of different manufacturing tasks, you need to configure specific parameters for each task, which takes some time. Modern robotic welding machines can achieve autonomous control by automatically adjusting welding parameters, but in most cases, manual parameter setting and adjustment are still required to ensure welding quality and efficiency.

Higher Initial Investment

One disadvantage of investing in robotic welding equipment is the high expenditure. Automated welding processes require a higher initial investment compared to manual welding processes. Manual welding may be more cost-effective, but you may still find it more expensive than automatic welding in the long run, and you will face labor costs, maintenance repairs, production waste costs, etc.

Part 2: What are the Components of a Robotic Laser Welding System?

The main components of the robot welding machine include robot system, laser system, welding head, control system and gas protection system, fixtures, etc. These parts cooperate with each other to complete the automatic welding and improve the welding quality and production efficiency. Knowing the main components of the robot welding machine can help you choose a welding machine that is more suitable for your production needs.

Robot System

The robot system is the core part of the robot welding machine. It usually uses a multi-joint robot arm as the basis, which has high speed, high precision and high flexibility. The robot system can be programmed and controlled by a computer or a dedicated controller to realize automated production.

Laser System

The laser system is another important part in the robot welding machine, which is used to provide the laser beam required for welding. The laser system mainly includes laser source, beam transmission system, beam focusing system and cooling system and other components. The quality and stability of the laser system have a very important influence on the welding quality.

Laser Welding Head

The welding head is the final part used by the robot welding machine for welding. It usually uses a hand-held or fixed welding head, which can be replaced according to different welding requirements. The welding head usually includes components such as a beam focuser, a gas shield, and a welding head.

Control System

The control system is an important part of the robot welding machine, which is used to realize the automatic control of the welding machine. The control system is usually composed of computer, PLC, electrical control system, etc., which can realize the monitoring and control of the automatic welding process and ensure the welding quality and production efficiency.

Gas Protection System

The gas protection system is the auxiliary equipment of the robot welding machine, which is used to provide shielding gas, protect the molten pool during welding, and prevent oxidation and pollution. Gas protection systems usually include gas cylinders, pressure reducers, flow meters, gas pipelines and other components.

Fixture and Clamping Equipment

The quality of the jig that holds the parts in place before welding is very important to the quality of the job done. The positioning of the parts needs to be highly repeatable and robust so that no movement occurs during the welding process. Welding robot manufacturers usually supply the bench, but not fixture provided.

Part 3: How to Choose the Right Robotic Welding System

When choosing a laser robot welding machine, you need to focus on the following factors. These points will ensure that you get a high performance, high efficiency robotic welding system that fits your production business.

Welding Requirements

Consider the type of materials that need to be welded, the thickness of the metal, and the type of weld required (e.g. butt weld, lap weld, or fillet weld). Choose a robot laser welding machine that is appropriate for the specific welding requirements.

Laser Type

The two main types of lasers used in robot laser welding machines are CO2 and fiber. CO2 lasers are better suited to thicker materials, while fiber lasers are better suited to thinner materials and offer greater power efficiency.

Robot Type

Consider the size and reach of the robot arm, as well as the number of axes of movement. This will impact the maximum size of the components that can be welded and the complexity of the welds that can be performed.

Automation Requirements

Consider the level of automation required, including the need for automatic component loading and unloading. It may be necessary to assemble a complete robot welding system with other automation equipment.

Service and Support

Choose a reputable manufacturer that offers adequate customer service and support, including technical assistance, training, and maintenance and repair services.

Budget

Consider the budget available for purchasing and operating the robot laser welding machine, including the costs of maintenance and repair, consumables, and operator training.

By considering these factors, you can select a robot laser welding machine that is best suited for your specific welding needs and budget. Of course, you will not always have a deep understanding of all welding machines. Before purchasing, you can consult professional laser equipment manufacturer DPLASER at any time, and we will wholeheartedly provide you with suitable suggestions.

Part 4: Robotic Welding Applications

Due to its high quality and high productivity, robotic welding has become important in metal and heavy industry, especially in the automotive industry where spot and laser welding are mostly used. Secondly, robot welding technology is also commonly used in precision electronic components, aerospace aircraft parts, circuit board (PCB) welding, mechanical parts manufacturing, and welding of large steel structural parts in the construction industry.

4.1 Robotic Welding in Automotive Industry

Laser welding has become a trend in automotive production. The use of laser welding in automobile production line can not only reduce the weight of the car body, but also improve the quality, safety, efficiency and cost-effectiveness of the auto parts.

Body Welding:

The most common welding in automobile production is body welding, which is a complex welding process that requires high-precision and high-efficiency. The robot welding machine can quickly and accurately complete the body welding task through automatic control, effectively improving production efficiency and welding quality.

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Engine Welding:

The auto engine is the core component of the automobile, and its welding quality affects the performance and safety of the automobile. The robot welding machine can achieve precise welding of engine parts through automatic control, improving welding quality and production efficiency.

Exhaust Pipe Welding:

The exhaust pipe is an important part of the rear of the car, which requires special welding techniques that are resistant to high temperatures and corrosion. The automatic robot welding machine can realize the precise welding of each part of the exhaust pipe, so as to ensure the performance and safety of the exhaust pipe.

Automobile Wheel Hub Welding:

Wheel hub is one of the key components of auto operation, and its welding quality is directly related to the driving safety and stability of the automobile. The robot welding machine can achieve high-precision and high-quality welding of the hub through automatic control, improving efficiency and welding quality.

The above is the application of robot laser welding machine system for auto manufacturing. The laser welding machine adopts the intelligent robot. It collimates the parallel light through the collimating mirror and focuses on the work piece to perform welding. It can perform flexible transmission and non-contact welding on the welding precision parts that are difficult to access for large molds.

4.2 Robot Welding Machines for Jewelry Welding & Mark

Welding and soldering

Robot welding machines can be used to weld and solder various parts of a jewelry item, such as clasps, chains, and rings. The precision and accuracy of the robot ensure that the welds are strong and consistent.

Engraving and etching
Robot welding machines can also be used to engrave or etch patterns and designs onto jewelry items. This can be done with a laser or other cutting tool attached to the robot arm.

Overall, the use of robot welding machine in the jewelry industry can improve precision, quality, and efficiency.

The Bottom Line:

Welding automation can help offset the skilled welder shortage while improving both productivity and safety. While some welding jobs can be completely automated, that’s often not the case for many tasks. However, as welding automation systems are rapidly improving, and becoming more commonly used, we will likely see welding automation ingrained in everyday welding tasks, even in small welding shops.

Learn about the advantages and disadvantages of welding automation and how your business could benefit from automation solutions, including cobotic welding.

Welding Automation Equipment

It’s easy to picture a production facility with tens or hundreds of robotic arms making welds on an assembly line, but, welding automation doesn’t refer to only welding robots, even if they are often crucial for automation.

Welding automation systems include welding positioners that allow easy access to oddly shaped parts, welding manipulators that maximize efficiency, turning rolls for pipe rotation, growing line systems for producing large tubular elements, and others. You can see a whole range of Red-D-Arc weld automation systems that can make many welding jobs significantly more productive and cost-effective.

Fully-Automated Welding

Fully-automated welding is commonly employed in mass fabrication, like in the automotive industry. Fully-autonomous systems do everything — machines load and unload parts to and from the weld cell, control the fixtures, complete the weld, and inspect the quality. Usually, complete automation doesn’t require much human involvement.

These systems are often expensive, large-scale, and employed for repetitive welds. However, the future may see more industries transition to fully-automated welding. As artificial intelligence advances and fully-automated welding systems become more flexible, they may pose the best solution to worker shortages and maximum ROI and productivity.

Semi-Automated Welding

Semi-automated welding significantly reduces human interaction with the welding process. However, operators are still needed, and it’s often an advantage if they are trained welders. These systems are usually more affordable than fully-automated setups. In addition, semi-automated welding is more flexible, requires a lower up-front investment, and introduces less equipment to your work environment. 

The future may see a rise in semi-automated welding, especially in small and medium-sized welding businesses. These systems can significantly improve the productivity of a welding operator. As a result, semi-automation can solve the challenges of worker shortages because one operator can complete more welds with higher efficiency.

Advantages of Welding Automation

Automating your welding processes has numerous benefits that can improve your ROI and productivity with fewer skilled operators. The essential benefits of welding automation are:

• Enhanced weld quality and repeatability
• Increased production output
• Reduced scrap and wasted parts
• Reduced operator training time compared to manual welding training
• Improved workplace safety
• Drastically reduced post-welding cleanup

Disadvantages of Welding Automation

• Some automation solutions can require a significant up-front investment; however, rental and lease options can eliminate the need for capital investment
• Traditional industrial robots require specialized expertise to program
• Large-scale systems may lack the desired flexibility for your welding business
• It may be challenging to introduce automated systems into your workforce due to workers’ fears of replacement

Cobot Welding Systems

In a way, you could say that the “future” of welding automation is already here. Solutions like collaborative robots, commonly known as cobots, have already proved fruitful in the current environment. You don’t necessarily need to fully automate your welding production, especially if you are a small or medium welding business. 

This is where cobot welding systems stand out. They are cost-effective, easy to get up and running, and work along with your workforce. So, you don’t need to completely transition from manual labor to large-scale, expensive, permanently fixed, fully-autonomous welding cells. In addition, cobots are more flexible than hard automated systems and significantly reduce the safety hazards present with common industrial robots since they are designed to be used collaboratively with workers.

The BotX robotic welding system addresses the skilled labor shortage through short or long-term rental, lease or purchase of an advanced, easy-to-use automated welding robot. Our innovative, on-demand model allows you to quickly scale up or down your welding operation using the BotX, which is hard to achieve with manual welding. BotX can weld complex parts in minutes, provide real-time monitoring and production data, and comes with 24/7 support. Your welding team can be up and running in hours with BotX because our automation specialists will be with you every step of the way to tailor the experience to your needs.

Cobots are designed to amplify the production rate of your welders by working with them. As a result, your welders (or trained BotX operators) can get more work done faster. You can’t quickly hire more welders to bid on a large project. But you can rent a BotX from Red-D-Arc and amplify your production rate and bid with confidence. That’s the power of weld automation.

What The Future Holds

The future of welding automation will need to address the ever-decreasing availability of skilled welders and the ever-increasing need for faster and higher-quality production. However, there likely won’t be a one-size-fits-all solution. Depending on the industry and business scale, the future may utilize cobot systems or fully automated, large-scale automation.

Another issue stifling automation progress is the cost of these systems. That’s why innovative solutions like renting or leasing these machines are crucial. Pay as you go lets you immediately have net gains as you bid on projects that were previously beyond your reach because you didn’t have the necessary workforce. 

Having the flexibility to bid on various projects and upscale/downscale your production is a competitive advantage that can make you stand out from other welding contractors. With the scarce welding force, it’s hard to run your business and jump from project to project with the confidence that you can do everything smoothly. But, the flexible, scalable, and collaborative welding automation systems can help your welding business stay ahead of the curve. 

If you are the only local contractor who bids with faster completion times and/or with a favorable price, you can lead the way as a preferred welding business. That’s what the future of welding automation must provide to the welding businesses dealing with labor shortages and a demanding market. 

Eventually, having automated welding systems running alongside manual labor may become a standard operative practice even in small welding shops. So, it’s wise to think about the future today. No industry is impervious to change. And adaptability is one of the essential tools at your disposal in an ever-changing industry like welding and fabrication.

Will Robots Replace All Human Welders?

A common fear among welders is that automation will replace them. While some industries and large-scale production can be fully automated, the whole industry won’t become fully autonomous in any perceivable future. Instead, the future is far more likely to use flexible  cobots, like the BotX™ cobot welding system, to amplify the skills and expertise of the welders. The best way to handle any fears is to remind your welding team that robots need the knowledge that they have in order to be used and that they are meant to be used as their tool, not to replace them.

However, as the demand for skilled labor grows, welding robots will have to pick up the pace. As a result, innovative solutions like the BotX cobot do provide a more accessible barrier to entry so that a trained BotX operator (not necessarily a welder) can easily use the cobot to produce quality welds.

Rent Or Lease Your Automation Equipment From Red-D-Arc

Red-D-Arc has a fleet of over 45,000 units of welding and cutting equipment strategically located in over 70 rental centers throughout the USA, Canada, France, United Kingdom, and Netherlands. Our weld automation specialists can work collaboratively with you to help you automate your welding business no matter the scale. 

It may not always be cost-effective to purchase your welding tools, and this includes automation equipment. Sometimes you’ll need a welding power source or a cobot for one job only, or its use won’t cover the ongoing maintenance cost. In addition, as the industry changes, so are the required welding equipment features. Therefore, for some businesses, owning expensive equipment can become an investment into a depreciating asset.

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