Mechanized welding is the first thought that comes to mind to any engineer when he realizes that the manual operation is not rendering the desired results. Now, from the thought to a reality some plan must be put into action. This article’s scope is to make it easy to understand how to set up mechanized welding in your own shop. Let’s start with the basics.
What is mechanized welding?
Mechanized welding refers to a way of applying welding in which the equipment requires involvement of the operator in response to visual observation of the welding. The mechanical device used holds the electrode, wire or workpiece while the welding is performed. The intervention from the operator is constant and required after every cycle.
This way of welding is used in a wide variety of industries, including automotive, aerospace, construction, and shipbuilding. It is particularly well-suited for applications where high productivity and weld quality are required.
Even though it can be a complex process, it can also be a valuable tool for improving productivity, quality, and safety in manufacturing operations.
The goal of mechanized welding is to improve productivity, part quality, and welding repeatability by reducing manual labor and increasing the consistency of welding parameters through automation.
Advantages and disadvantages of mechanized welding
When comparing mechanized welding with other ways to achieve higher production efficiency, like welding automation, or with manual labor, some advantages and disadvantages can immediately be perceived. Let’s take a look at them.
Advantages of mechanized welding
Increased productivity and efficiency: Can be much faster than manual welding, especially for repetitive welds.
Improved weld quality: Can produce more consistent and reproducible welds than manual welding.
Reduced operator fatigue: Can reduce the amount of physical labor required by the operator, which can lead to improved safety and productivity.
Improved safety: Can help to protect the operator from harmful fumes, heat, and arc radiation.
Reduced rework: Rework is usually caused by human error. Mechanized welding can help to reduce the number of defects in welds, which can lead to reduced rework costs.
Reduced labor costs: Can help to reduce the number of workers needed to perform welding operations. Faster cycle times and less rework ultimately reduce production costs.
Improved repeatability: Programmed machines perform repetitive welds consistently with less defects. These welds are more consistent in size and shape than manual welding.
Customization and accessibility: Mechanized parameters can be programmed for specific applications. Mechanized systems can weld hard to reach joints.
Documentation: Data capture capabilities support defect tracking and process improvements.
Disadvantages of mechanized welding
High initial investment cost: Significant investment required for automation equipment and integration.
Limited flexibility: Mechanized welding equipment is often designed for specific applications, which can limit its flexibility. Changeovers between different parts can take time. Weight and envelope of parts must work within equipment capabilities.
Requires skilled operators: Requires skilled programmers to optimize mechanical motion and parameters. Workers require new skills in mechanized welding operations and troubleshooting.
Maintenance needs: Robust preventative maintenance required on mechanized components.
Common applications of mechanized welding
Mechanized welding is a rapidly growing industry, as businesses increasingly look for ways to improve their productivity and efficiency. With its many advantages, mechanized welding is well-positioned to continue to grow in the coming years. Mechanized welding is used in a wide variety of industries and applications, including:
Automotive: It is used to weld the various components of a car body together, including the frame, panels, and doors. It is also used to weld engine and transmission components together. Mechanized MIG welding allows high precision at fast cycle times.
Aerospace: It is used to weld the components of aircraft and spacecraft together, including the wings, fuselage, and engine components. It is also used to weld fuel tanks and landing gear assemblies together.
Construction: It is used to weld structural steel beams and columns together in bridges and buildings. It is also used to weld pipelines and pressure vessels together.
Shipbuilding: It is used to weld the hull and superstructure of ships together. It is also used to weld piping and machinery components together.
Heavy equipment: It is used to weld the components of heavy equipment, such as excavators, bulldozers, and cranes, together.
Pipe welding: Tractors, positioners, and seamers mechanize pipe welding in skilled trades like pipelines, boilers, and offshore platforms.
Electronics: It is used to weld the components of electronic devices, such as circuit boards and semiconductors, together.
Food/beverage: Stainless steel tanks, vessels, and piping for food processing are welded using mechanized methods, like orbital welding.
Medical devices: It is used to weld the components of medical devices, such as pacemakers and surgical implants, together.
Shipbuilding: Ship hulls and structures are joined using huge automatic welding systems and manipulators.
Railroad: Tank cars, locomotive frames, and rail stock are welded using automation.
Equipment for mechanized welding: Welding carriages
Welding carriages are mobile devices that are used to guide and support a welding torch, a cutting torch, or laser beam along the weld joint. They are typically used for mechanized welding, which is a process in which the welding parameters are controlled mechanically or electronically.
Welding carriages can be used to weld a variety of materials, including steel, stainless steel, aluminum, and titanium. They can also be used to weld a variety of joint types, including butt joints, lap joints, and corner joints. Usually, they are used to weld large workpieces like pipelines.
Features of welding carriages
Welding carriages provide a versatile method of mechanized welding for operators. They simplify circumferential welds on tanks, vessels, boilers, and large pipes. These are some of their main features:
- Mounting: The compact carriage frame is mounted around the cylinder or track at the desired weld joint location
- Propulsion: An internal drive system propels the carriage along the axis of the cylinder as welding is performed
- Wire feed: An integrated wire feeder provides consistent welding wire to the torch as the carriage travels
- Torch manipulation: Arms pivot and guide the welding torch to maintain proper angles and offsets
- Travel speed: The carriage speed is set to provide optimal weld bead overlap and heat input as it progresses
- Guidance: Grooved wheels, tracks or magnets ensure the carriage remains aligned axially during travel
- Programming: Parameters like wire feed speed, arc voltage, oscillation width, are programmed based on welding requirements
- Monitoring: Built-in sensors can monitor factors like arc voltage for automated adjustments
- Safety: Proper guarding prevents contact with moving parts during automated carriage operation.
How to use a welding carriage
To use a welding carriage for mechanized welding, the following basic steps should be followed:
- Select the appropriate welding carriage for the application: There are a variety of welding carriages available, so it is important to select one that is compatible with the welding machine and the materials being welded
- Position the welding carriage: The welding carriage should be positioned on the workpiece so that the welding torch or laser beam is aligned with the weld joint
- Secure the workpiece in place: The workpiece should be securely clamped or otherwise secured to prevent it from moving during welding
- Set the welding parameters: The welding parameters, such as the welding speed, wire feed rate, and power, should be set according to the welding procedure specification (WPS)
- Start the welding process: Once the welding parameters have been set, the welding process can be started by activating the welding machine
- Monitor the welding process: The welding process should be monitored to ensure that the weld is being formed properly
- Stop the welding process: Once the weld has been completed, the welding process should be stopped by deactivating the welding machine.
Benefits of using welding carriages
Here are some of the benefits of using welding carriages for mechanized welding:
Increased productivity: Can significantly increase the productivity of welding operations. This is because they can travel along the weld joint at a much faster pace than a human welder.
Improved weld quality: Can help to improve the quality of welds by providing consistent and precise alignment of the welding torch or laser beam.
Reduced operator fatigue: Can help to reduce operator fatigue by eliminating the need for the operator to manually guide the welding torch or laser beam.
Improved safety: Can help to improve safety by reducing the operator’s exposure to welding fumes and heat.
Orbital welding
Orbital welding is a type of automated welding process that uses a rotating welding head to create a circumferential weld around a joint. It is a precise and repeatable process that can be used to produce high-quality welds in a variety of materials, including steel, stainless steel, and aluminum.
This kind of mechanization enhances quality, consistency, and productivity for circumferential welding applications like piping, boilers, hydraulic cylinders, and tanks.
Orbital welding is commonly used in the following industries:
- Aerospace
- Automotive
- Electronics
- Food and beverage
- Medical devices
- Oil and gas
- Pharmaceutical
- Power generation
- Semiconductor
- Shipbuilding
Features of orbital welding
These are some of the main features of orbital welding:
- Rotation: The welding head rotates 360° around the workpiece on a compact enclosed track
- Programming: Welding parameters like speed, arc voltage, gas flow is programmed into the system
- Precision: Orbital welding produces very precise, high quality and repeatable welding qualities in pipes or cylinders
- Portability: Smaller orbital weld heads can be brought to the pipe rather than requiring movement
- Positioning: The welding head tilts to keep optimal aim and arc characteristics as it rotates around the pipe
- Speed control: Precisely controls the travel speed for uniform weld bead placement
- Documentation: Built-in monitoring and data logging of weld parameters for quality control
- Safety: Enclosed operation poses lower risks compared to manual pipe welding.
Benefits of using orbital welding
Orbital welding is used for welding mechanization because it offers several advantages over manual welding, including:
Increased productivity: Can significantly increase the productivity of welding operations, especially for repetitive welds.
Improved weld quality: Can produce more consistent and reproducible welds than manual welding.
Reduced operator fatigue: Eliminates the need for manual operation, which can reduce operator fatigue and improve safety.
Improved safety: Can help to improve safety by reducing the operator’s exposure to welding fumes and heat.
Equipment required for orbital welding
Orbital welding systems typically consist of the following components:
Welding head: The welding head contains the welding torch and the mechanisms for rotating the torch around the joint.
Power source: The power source provides the electrical power needed to operate the welding machine.
Wire feeder: The wire feeder feeds the filler metal into the welding joint.
Control system: The control system programs and operates the orbital welding system.
How to use orbital welding equipment
By following these steps, you can use orbital welding to safely and efficiently produce high-quality orbital welds.
- Select the appropriate orbital welding system for the application: There are a variety of orbital welding systems available, so it is important to select one that is compatible with the materials being welded and the desired weld quality
- Prepare the joint for welding: The joint should be clean and free of contaminants
- Position the orbital welding system on the joint: The orbital welding system should be positioned so that the welding torch is aligned with the weld joint
- Secure the joint in place: The joint should be securely clamped or otherwise secured to prevent it from moving during welding
- Set the welding parameters: The welding parameters, such as the welding speed, wire feed rate, and power, should be set according to the welding procedure specification (WPS)
- Start the welding process: Once the welding parameters have been set, the welding process can be started by activating the orbital welding system
- Monitor the welding process: The welding process should be monitored to ensure that the weld is being formed properly
- Stop the welding process: Once the welding has been completed, the process should be stopped by deactivating the orbital welding system.
Other equipment used for mechanized welding
Mechanized welding enhances productivity and quality for most high-volume manufacturing, especially in industries dealing with large components. The equipment used for mechanized welding can vary depending on the specific process and application.
When applying mechanized welding, the welding parameters in the equipment can be intervened at any moment by the operator. As a matter of fact, the operator must keep an eye on the welding beam during the whole operation to ensure the appropriate performance of the equipment. This is one of the key differences with automated welding, where there is no need for such care.
Some other equipment needed for mechanized welding are:
Positioning equipment: Positioning equipment is used to hold the parts being welded in the correct position during welding. Rotate parts like pipes into ideal angles for welding access. Pivot, tilt, and roll capabilities. This may include welding positioners, rotators, and manipulators.
Seam welding machines: Shuttle welding heads along a part to create continuous seams. Useful for longer parts.
Workpiece clamps & fixtures: Secure parts firmly and properly for automated welding processes.
Welding turntables: Rotate bulky cylindrical parts like tanks during circumferential seam welding.
Control systems: They are used to program and operate mechanized welding equipment. This may include programmable logic controllers (PLCs) and human-machine interfaces (HMIs).
Mechanized welding: Last thoughts
Mechanized welding offers a number of advantages over manual welding. It is only natural that companies are trying to apply it in their operations. The process to insert mechanized welding as part of your productive process is simple if someone is there to guide you. We have several decades helping companies to set up mechanized welding operations. Feel free to reach out to us at your earliest convenience.
