Welding automation is, hands down, the difference between an average production line and a superb fabrication.
It is safe to say that welding automation is unstoppable. According to a report by the International Federation of Robotics (IFR), there were 535,000 welding robots in operation worldwide in 2022. This represents an increase of 16% from 2021.
Whether your company owns welding automation equipment, or you are trying to implement it in the near future, this article will provide the basis about the topic.
What is welding automation?
Welding automation is the use of machines and robots to perform welding operations, with the minimum intervention, if any, from operators. This can include the entire welding process, from loading and unloading the parts to be welded, to positioning the parts, to welding them together, in complex processes.
The purpose is to use equipment, machinery, and technology to automate welding processes for enhanced quality, productivity, and efficiency.
How far welding automation has progressed
The automotive industry is the largest user of welding robots, accounting for 55% of all welding robots in operation in 2022. Other major users of welding robots include the electrical and electronics industry (13%), the metalworking industry (12%), and the general machinery industry (9%).
The Asia-Pacific region is the largest market for welding robots, with 427,000 units in operation in 2022. China is the largest single market for welding robots, with 368,000 units in operation.
Other major markets for welding robots include Europe (81,000 units), North America (17,000 units), and Latin America (10,000 units).
The use of welding robots is expected to continue to grow in the coming years, as businesses seek to improve productivity, quality, and safety.
Trends in welding automation
There are a few trends in the welding automation market, including:
The increasing use of collaborative welding robots: Collaborative welding robots, also known as cobots, are designed to work safely alongside human workers. Cobots are becoming more popular in a variety of industries, including the automotive and the electronics industry.
The development of more intelligent and autonomous welding robots: These are becoming more intelligent and autonomous. This is due to advances in artificial intelligence and machine learning. More intelligent and autonomous welding robots will be able to adapt to changes in the welding environment and perform more complex welding tasks.
The increasing use of welding robots in new industries: They are being used in new industries, such as the construction and the food and beverage industry. As welding robots become more affordable and versatile, they are expected to be used in an even wider range of industries in the future.
Factors driving the growth of welding robots
The future of welding robots is bright. They are expected to play an increasingly important role in manufacturing and other industries in the years to come. There are several factors driving the growth of welding robots, including:
The increasing demand for high-quality welds: This equipment can produce high-quality welds with consistent repeatability. This is important for a variety of industries, including the automotive, the aerospace, and the medical device industry.
The need to improve productivity: Welding automation can help to improve productivity by automating repetitive welding tasks. This can free up human workers to focus on more complex tasks.
The need to improve safety: Can help to improve safety by reducing the operator’s exposure to hazards associated with welding, such as fumes, heat, and radiation.
The decreasing cost of welding robots: The cost of welding robots has decreased in recent years, making them more affordable for a wider range of businesses.
Advantages and disadvantages of welding automation
Welding automation is a complex and rapidly evolving field, but it has the potential to revolutionize the way that welding is done. Nevertheless, it is important to mention the advantages and disadvantages it has.
Advantages of welding automation
Increased productivity: Can weld much faster than manual welders, especially for repetitive welds. This can lead to significant productivity gains.
Improved weld quality: Can produce more consistent and reproducible welds than manual welders. This is because automated welding systems are not subject to the same human factors, such as fatigue and distraction. Automated systems make fewer errors leading to less rework.
Reduced operator fatigue: Eliminate the need for manual operation. This can reduce operator fatigue and improve safety. Robotic welders can access hard to reach joints ergonomically.
Improved safety: Help to improve safety by reducing the operator’s exposure to hazards associated with welding, such as fumes, heat, and radiation.
Reduced costs: In the long term, welding automation can help to reduce costs by improving productivity and quality and reducing waste.
Documentation: Automated data collection improves defect traceability and process control.
Disadvantages of welding automation
High initial investment cost: These systems can be expensive to purchase and install.
Requires skilled operators: They require skilled operators to program and operate them safely and efficiently. Training is a must when shifting from manual or mechanized operation to automation.
Limited flexibility: Automated welding systems are often designed for specific applications, which can limit their flexibility.
Ongoing maintenance: Regular preventative maintenance is required on automation systems. Since is a heavy investment, it is essential to set up a maintenance program.
Common applications of welding automation
Automating repeatable welds boosts production efficiency in almost every heavy manufacturing industry. Welding automation is used in a wide variety of industries, but some of the most common applications include:
Automotive: It is used to weld a variety of automotive components, including chassis frames, body panels, and engine manifolds.
Aerospace: It is used to weld aircraft and spacecraft components, such as wings, fuselages, and rocket engines. Aircraft, rocket, and satellite production all benefit from precision programmed welding methods.
Heavy machinery: Excavators, bulldozers, cranes, mining equipment rely heavily on automated welding in fabrication.
Construction: It is used to weld structural steel for bridges, buildings, and other structures.
Appliances: High volume appliance manufacturing like washing machines, dryers, and refrigerators use automated welding.
Shipbuilding: Automated systems allow efficient welding of ship hulls, decks, and interior compartments.
Electronics: Robotic lasers weld small electrical components and connections requiring precision. It is used to weld circuit boards and other electronic components.
Specific uses of welding automation
Welding automation is a powerful tool that can help businesses improve productivity, quality, safety, and cost-effectiveness. As welding automation technology continues to develop, it is likely to become even more widely used in the future. Here are some specific examples of welding automation applications:
Welding automotive body panels: They are used to weld automotive body panels together. This is a high-volume, repetitive task that is well-suited for automation.
Welding aircraft wings: They are used to weld aircraft wing spars and ribs together. This is a complex task that requires high precision and repeatability.
Welding structural steel for bridges: They are used to weld structural steel beams and girders together. This is a heavy-duty task that requires high-power welding equipment.
Welding ship hulls: They are used to weld the plates that make up the hull of a ship together. This is a large-scale task that requires a high degree of coordination between multiple robots.
Welding circuit boards: They are used to weld the components on circuit boards together. This is a high-precision task that requires very small welding beads.
Welding pipelines: Automatic mechanized welders are critical for economic long seam welding of pipes.
Welding furniture: Robotic welders create repeating furniture frame welds for tables, chairs, shelving that enhance consistency.
Food/beverage: Stainless steel processing vessels and equipment are ideally suited to automated welding techniques.
Equipment for welding automation: Welding robots
Welding robots are machines that can be programmed to move a welding torch or laser beam along the welding path. They integrate precision robotic arm manipulation with advanced welding controls and peripherals for automated, high-quality welding. This equipment is used in a wide variety of industries, including automotive, aerospace, construction, and shipbuilding.
Types of welding robots
There are two main types of welding robots:
Cartesian robots: Also known as XYZ robots. They have three linear axes that move the welding torch or laser beam in three dimensions. Cartesian robots are typically used for welding simple parts.
Articulated robots: These robots have multiple joints that allow them to move in a wide range of directions. Articulated robots are typically used for welding complex parts.
Advantages of welding robots
Welding robots offer a few advantages over manual welding, including:
Increased productivity: Can weld much faster than manual welders, especially for repetitive welds.
Improved weld quality: Can produce more consistent and reproducible welds than manual welders. This is because welding robots are not subject to the same human factors, such as fatigue and distraction.
Reduced operator fatigue: Eliminate the need for manual operation. This can reduce operator fatigue and improve safety.
Reduced costs: In the long term, welding robots can help to reduce costs by improving productivity and quality and reducing waste.
Improved safety: Can help to improve safety by reducing the operator’s exposure to hazards associated with welding, such as fumes, heat, and radiation.
Welding robot components
Welding robots typically consist of the following components:
Robotic arm: The articulated robotic arm provides movement in multiple axes to position and manipulate the welding torch or laser beam along the weld path.
Welding torch or head: It contains the welding torch or laser beam, and the mechanisms for feeding the welding wire or shielding gas.
Programming or tech pendant: A handheld programmer’s interface used to teach the robot motions and program weld parameters.
Controller: The robot controller stores programmed instructions and coordinates the robotic arm movement as well as peripherals.
Power source: The power source provides the electrical power needed to operate the welding robot and welding torch. In some brands it is part of the equipment, in others it can be an assembly with welding machines from other brands.
Wire feeder: This feeds the welding wire to the welding torch.
Shielding gas equipment: This protects the weld from contamination.
Safety equipment: Welding robots are typically equipped with safety features, such as guards and sensors, to protect the operator and the robot itself.
Future of welding robots
Welding robots are becoming increasingly sophisticated and capable. This is due to advances in robotics technology, welding technology, and artificial intelligence.
In the future, welding robots are expected to become more autonomous and intelligent. They will be able to sense their environment and adapt their welding parameters accordingly. This will allow them to produce even higher quality welds and operate in more challenging environments.
Welding robots are also expected to become more affordable and accessible to businesses of all sizes. This will make it possible for more businesses to benefit from the advantages of welding automation.
Overall, the future of welding robots is bright. Welding robots are expected to play an increasingly important role in manufacturing and other industries.
Equipment for welding automation: Cobots
Welding cobots, also known as collaborative welding robots, are a new type of welding robot that is designed to work safely alongside human workers. Cobots are typically smaller and less powerful than traditional welding robots, but they are also more agile and easier to program. This makes them ideal for a wide range of welding applications, from simple repetitive tasks to complex multi-step processes.
They are used in a wide variety of industries, including automotive, aerospace, construction, and shipbuilding. Cobots are particularly well-suited for applications where high quality and repeatability are required.
Specific uses of welding cobots
Welding cobots are collaborative robots designed to work safely alongside human welders to enhance productivity and quality. Some ways they are used:
Manipulating parts: The cobot can handle, reorient, and position components for the welder, reducing strain and increasing speed.
Multi-pass welding: Cobots perform primary welds allowing the welder to follow with finishing and detailing welds.
Continuous welding: For long seams, the cobot provides continuous welds while the operator monitors quality.
Accessing confined spaces: Compact cobots can access tight welding joints that are ergonomically difficult for a human.
Reducing positioning time: The cobot instantly and consistently locates parts, freeing up time for the welder.
Pre-tacking: Quickly tacking components prior to the final critical welds done manually.
Benefits of welding cobots
Cobot collaboration enhances productivity while preserving operator flexibility to inspect and do finish work. Their safety features allow close human-robot welding cooperation. Here are some of the key benefits of using welding cobots:
Improved safety: They are designed to work safely alongside human workers. They have a number of safety features, such as force limiting and collision detection, that help to prevent accidents.
Increased productivity: Can automate repetitive welding tasks, freeing up human workers to focus on more complex tasks. This can lead to significant productivity gains.
Improved quality: These can produce high-quality welds with consistent repeatability. This is because cobots are able to move the welding torch with great precision and accuracy.
Reduced costs: Can help to reduce labor costs and improve efficiency. This can lead to significant cost savings over the long term.
Reducing fatigue: By assisting with handling heavy parts, the cobot reduces fatigue and injury potential.
Consistent path following: Cobots can accurately trace pre-programmed complex 3D weld paths.
Welding training: Simulate welding motions while the trainee focuses on mastering technique.
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Automation is the present and the future
Equipment for welding automation: Orbital welding
Orbital welding equipment is used to create high-quality, precision welds in a variety of metals, including steel, stainless steel, titanium, and aluminum. Orbital welding heads are capable of producing both fusion and resistance welds and can be used to weld a wide range of shapes and sizes.
Depending on the brand, the orbital welding equipment can be highly automated. This is specially used in the pharma and food industry, where pipes require highly precise welds and values need to be stored to be repeated.
Orbital welding components
Orbital welding equipment typically consists of the following components:
Orbital welding head: It is the heart of the orbital welding system. It contains the welding torch, wire feeder, and shielding gas system. MIG (GMAW) or TIG (GTAW) torch integrates seamlessly with the rotating weld head. Compact welding heads mounted on a rotating ring gear follow the weld joint as they orbit the workpiece.
Orbital welding power source: The power source provides the electrical power needed to operate the orbital welding head.
Orbital welding controller: The controller programs, stores, and operates the orbital welding head. Programmable controls coordinate the rotating weld head speed, arc start/stop, gas flow, arc characteristics, etc.
Orbital welding positioning equipment: It is used to hold and position the parts being welded during the orbital welding process. Circular cam, wheel, or magnet tracking ensures the weld head smoothly follows the pipe axis as it orbits.
Shielding gas: Provides inert shielding gas like argon or helium to protect the weld puddle and prevent oxidation.
Orbital welding safety equipment: It protects the operator from hazards associated with orbital welding, such as fumes, heat, and radiation.
Advantages of orbital welding
Orbital welding offers several advantages over other welding processes, including:
High quality: It is capable of producing high-quality welds with minimal heat input and distortion.
Precision: It is a very precise process and can be used to produce welds with tolerances of up to ±0.001 inches.
Repeatability: It is a repeatable process, which means that it can be used to produce consistently high-quality welds.
Automation: Can be completely automated, which can help to improve productivity and reduce costs.
Industries that use orbital welding
Orbital welding is a versatile and powerful welding process that can be used to produce high-quality welds in a variety of materials and industries. Some of the industries that use orbital welding the most are:
Aerospace: It is used to weld aircraft and spacecraft components.
Automotive: It is used to weld automotive components, such as fuel lines and exhaust systems.
Chemical processing: It is used to weld pipes and vessels for chemical processing applications.
Food and beverage: It is used to weld pipes and vessels for food and beverage processing applications.
Pharmaceutical: It is used to weld pipes and vessels for pharmaceutical processing applications.
Semiconductor: It is used to weld pipes and vessels for semiconductor manufacturing applications.
Other equipment for welding automation
Welding automation 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. In addition to the above equipment, welding automation may also require other equipment, such as:
Welding seam trackers: They ensure that the welding torch or laser beam is aligned with the weld joint.
Welding vision systems: These systems inspect welds for defects.
Welding data acquisition systems: These systems collect data on the welding process, which can be used to monitor and improve the welding process.
Welding automation: Last thoughts
Welding automation equipment can be complex and expensive. However, it can be a valuable investment for businesses that need to improve their productivity and efficiency.
There is a wide range of automated welding equipment available to suit various production needs, part sizes, and welding processes. If you feel overwhelmed due to all the variables available, consult with an expert can help. We have been helping companies to set up welding automation operations for decades. Feel free to reach out to us whenever you are ready to move forward.
