How Robotic Welding Leads To Increased Uptime And Efficiency

Since the 1950s, robotic welding has become far more streamlined. While manual welding still has a place in 21st-century manufacturing, automated welding is the next best investment. 

As more engineers start to understand robotic processes, companies’ needs and expectations are continuing to change. Today, most manufacturers have found a constant need to implement new advanced technologies as they look for new ways to increase efficiency and uptime. 

 

How Robotic Welding Works

An automated welding cell is made up of components that work together to heat and melt material. These components include elements that make up the welding process. Accessories and safety features are added to ensure a smooth operation. By understanding the basic components of a welding cell, the more crucial training is to the robotic welding process.

 

Wire Feeder

The wire feeder moves filler wire into the robot at a programmed rate. This is used to add material to the weld for joint support.

Welding Robot 

This typically includes the robot and the tool at the end of the arm, whether it consists of a manipulator or torch. These robots normally come in two variations: Articulators and rectilinear. Rectilinear robots can move their functional arm in three directions whereas the articulator robots can use their rotating joints for more free movement and range of motion out of the dimensions. 

Wire Cleaner

The wire cleaner removes spatter from the torch nozzle between cycles. This helps prolong the condition of the equipment. 

Torch

In order to heat and join metals together, this component uses power flowing to an electrode. Arc welding cells usually have an apparatus and air cooler unit included. 

Work Area

Parts are normally held here for robots to weld. Fixtures hold these parts in place as the robotic welder completes the task. 

Controller 

This is essentially the brain of the robotic process. By using stored programs, the robot receives instructions and supplies power.

Teach Pendant 

 An interface system that an operator uses to manually move the robot, store new programs, and set welding parameters. 

Welding Power Supply 

This component supplies the welding its power. It varies in size and performance depending on what unit needs to be welded. 

Stack Light 

This light shows what the cell is currently working on. The red light would indicate an emergency, the orange light would show that the robot is currently being programmed and the green light would mean the unit is up and running. 

Operation Box

To operate a unit from start to finish, this is where operators can access the controls for each function. 

Safety Features

To prevent harm in the workplace, robotic welding processes will typically come with safety features. Some of these include fences, arc shields, access doors, and many others that have the ability to reduce exposure to potential risks. 

 

Advantages of Robotic Welding 

Uptime & Efficiency

When it comes to throughput, manual welders work 8+ hour shifts and are far more prone to take breaks. While they still remain an essential part to the industry, it becomes a challenge to keep up with robotic uptime. 

Robotic welding processes don’t need to take breaks, they work around the clock and can achieve uptime levels of 90%. Manual welders tend to max out efficiency at a level of 20%, which means manual processes require more maintenance and downtime in comparison to their automated counterparts. 

Increase Revenue

Robotic welding allows for more cost savings while they increase productivity and efficiency. With several decades of robotic deployment, manufacturing companies can confidently rely on robotics delivering ROI in a reasonable amount of time. When those returns are achieved, other forms of outsourced investments are reduced. 

Quality Welding 

Even some of the best welders can’t always reproduce identical results each time. Depending on the specifics, it could mean that there is a substantial amount of time and cost at stake for work and costs diverted to rework or scrapping. 

On the other hand, an automated welding system is programmed with the very same motions and parameters to achieve a weld the same way in every cycle. The results would be incredibly noticeable when it comes to quality and consistency. 

 

How To Improve Robotic Welding Performance

Here are the 3 ways to improve the performance of robotics during the welding process.

Wire Feeding 

Poor wire feeding in terms of short liners can lead to burn backs. By using a spring-loaded system or monitoring the feeding, this ensures a smoother welding process.

Contact Life

A contact tip diameter needs to have the right wire size in order to function efficiently. It’s also important to keep the wire tip clean with compressed air to avoid build-up and debris. To reduce costs and extend the life span, using rotating contact tips will be beneficial. 

The Consumables 

To avoid problems in the long run, choosing the right consumables is key. Where preventative maintenance is concerned, contact tips require the right consumables in order to last longer and help optimize the way robotic processes perform. 

 

 

What A High-Quality Welding System Looks Like

What really makes a good welding system? Not only do good manufacturers invest in quality trained professionals, but they invest in quality robotic processes to ensure efficiency and value. It all starts by monitoring MIG guns, the right types of consumables and finding the right peripherals for robotics.

MIG GUNS 

With proper amperage and cooling capacity, MIG guns must suit the needs of a specific model.  Purchasing a MIG gun with more amperage than capacity is going to result in unnecessary costs. 

CONSUMABLES 

When choosing contact tips, nozzles and liners, manufacturers will keep various applications in mind. Standard duty consumables should be used for low amperage applications and applications with shorter times. Heavy duty consumables are to be used with high amperage or longer application times to reduce the amount of charging.

PERIPHERALS 

Peripherals make up additional pieces that a robotic weld system needs. It’s easy to maximise efficiency and performance when the right peripherals are used. They do pose a bit of a hefty upfront cost, however, the ROI results prove to be worth it. There are certain types of peripherals that can protect these components and increase efficiency in the long run.  

Ready to increase uptime & efficiency for your business? YASKAWA is here to assist you, contact us for more information.