How Do Welding Robots Work
Welding robots work by using automation to weld.
They can be automatic or semi-automatic systems.
In an automatic system, parts are fed in and clamped for the robot to weld, while in a semi-automatic system, an operator enters the robot cell and removes completed welds.
Robotic welding is faster and more productive than manual welding, and it has been around for over 60 years.
Different types of welding robots are used based on the welding processes they employ, such as resistance spot welding, collaborative welding, shielded metal arc welding, gas metal arc welding, gas tungsten arc welding, laser welding, and plasma welding.
Each type of robot has its own advantages and applications, and the welding industry continues to evolve with advancements in robot and cobot welding technologies.
Did You Know?
1. Welding robots use a technology called “sensing arc feedback” to detect changes in the welding process and automatically make adjustments, resulting in precise and high-quality welds.
2. Some welding robots utilize a technique called “tandem welding,” where two welding torches work simultaneously in a synchronized fashion, allowing for faster welding speeds and increased productivity.
3. To ensure safety, welding robots are equipped with advanced sensors that can detect and prevent collisions with objects or humans in their vicinity.
4. Welding robots often employ a teaching function, where an operator manually guides the robot arm through the welding motions, and the robot “learns” and replicates those movements for future welds.
5. Welding robots use special software programs that can simulate and optimize the welding process, helping to reduce errors, minimize waste, and improve efficiency.
Introduction To Welding Robots
Robotic welding is a fascinating technology that has revolutionized the welding industry. By utilizing a welding robot arm, this form of welding automation has significantly increased productivity and efficiency. Unlike manual welding, where a welder is required to perform the welding process, robotic welding eliminates the need for human intervention, resulting in faster production rates and higher quality welds.
There are two main types of robotic welding: automatic and semi-automatic. In automatic robotic welding, parts are fed into the system through either a conveyor or a magazine. These parts are then clamped in place for the robot to begin the welding process. On the other hand, semi-automatic robotic welding involves an operator entering the robot cell to remove the completed weld and position the next pieces for the robot to weld. Both types of robotic welding have their own benefits and are used in different manufacturing settings.
It is important to note that robotic welding has been in existence for more than 60 years. The first industrial robot, known as Unimate, was invented by George Devol in 1954 and was used by General Motors for welding operations. Since then, the industrial robot industry has grown exponentially, with continuous advancements in robot design, control, and mobility. Today, smaller collaborative robots, also known as Cobots, have been invented to work alongside humans, further enhancing the capabilities of robotic welding.
Types Of Robotic Welding
Robotic welding encompasses various types that employ different welding processes. Each type presents unique characteristics and finds applications across diverse industries. The commonly used types of robotic welding include:
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Resistance spot welding: This type is widely employed in the automotive manufacturing industry. It utilizes larger electrical currents to join multiple sheets in a single location. Typically, resistance spot welding robots are articulating robots with 2-10 axes. Equipped with a high-resolution servo motor encoder, they ensure precise control over the welding gun’s motion.
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Collaborative welding: Also known as cobot welding, this method utilizes a 6-axis robotic arm with a welding torch as its end effector. Unlike traditional robotic welding systems, cobot welding does not necessitate a separate robot cell for housing. It enables human-robot collaboration, offering flexibility and adaptability in various work environments. Cobot welding is easy to deploy, redeploy, and program, making it a popular choice in industries where versatility is crucial.
Other types of robotic welding include:
- Shielded metal arc welding
- Gas metal arc welding
- Gas tungsten arc welding
- Laser welding
- Plasma welding
In conclusion, understanding the different types of robotic welding and their respective applications is essential for industries seeking efficient and versatile welding solutions.
Advantages And Limitations Of Welding Robots
The use of welding robots offers numerous advantages over traditional manual welding.
One of the main benefits is increased speed and productivity. Robots do not require breaks and can continuously work without fatigue, leading to higher production rates and the ability to produce more parts within a given timeframe.
Moreover, welding robots can achieve up to 85% efficiency compared to only 20% for skilled human welders. They also have up to 95% arc-on time, ensuring optimum performance and minimal idle time.
Another advantage of welding robots is their ability to maintain constant weld speed, current, and other variables. This consistency leads to high weld quality every time, reducing the likelihood of welding mistakes and the generation of waste and scrap. Additionally, robots utilize consumables like fillers and nozzles more effectively, resulting in reduced waste and cost savings.
However, it is important to acknowledge the limitations of welding robots as well. The programming and operation of welding robots require complex skills and specialized training for workers. Initial investment costs in machinery, jigs, and training can also be considerable. However, it is worth noting that the return on investment for robotic welding systems can range between one to three years, making it a viable long-term solution for companies.
- Advantages of welding robots:
- Increased speed and productivity
- Higher production rates
- Achieve up to 85% efficiency
- Up to 95% arc-on time
- Consistent weld quality
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Reduced waste and cost savings
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Limitations of welding robots:
- Require complex skills and specialized training
- Considerable initial investment costs
“The use of welding robots offers advantages such as increased speed and productivity, higher production rates, and improved weld quality. However, it is important to consider the complex skills required for programming and operation, as well as the considerable initial investment costs.”
Types Of Welding Robots Based On Processes
As previously mentioned, there are various types of welding robots that can be classified based on the welding processes they employ. Each type has its own specific applications and benefits. Let’s take a closer look at some of these notable types:
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Resistance Spot Welding Robots: These robots are commonly used in the automotive manufacturing industry. They are capable of joining sheets in a single location using larger electrical currents. Resistance spot welding robots employ articulating robots with a range of 2-10 axes and utilize a servo motor equipped with a high-resolution encoder to control the motion of the welding gun.
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Collaborative Welding Robots: Also known as cobots, these are 6-axis robotic arms with a welding torch effector that can work alongside humans. Unlike traditional welding robots, cobots do not require a separate welding robot cell for housing, offering flexibility and adaptability in various work environments. They are easy to deploy, redeploy, and program, making them suitable for industries where versatility is crucial.
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Shielded Metal Arc Welding (SMAW) Robots: Commonly referred to as stick welding robots, these robots create an arc between a consumable flux electrode and the welded material. When using SMAW robots, consideration of tool center point (TCP) variation is necessary.
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Gas Metal Arc Welding Robots (GMAW/MIG): These robots are used for high deposition rates and can weld various materials such as stainless steel, copper, nickel, carbon steel, and aluminum.
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Gas Tungsten Arc Welding Robots (GTAW/TIG): GTAW robots are specifically utilized for welding thin parts and achieving precise welds. These systems are automatically controlled and maintain arc length with automatic voltage control. GTAW robotic welding systems use cameras for joint location tracking and error detection, offering precise welds for thin materials.
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Laser Welding Robots: These robots utilize a focused laser beam as the energy source for welding. They can perform heat conduction or deep laser welding and are often used in industries like medical devices and aerospace. The flexibility of laser welding robots allows them to weld materials of different thicknesses from various angles and directions.
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Plasma Welding Robots: Plasma welding robots use a plasma arc as the heat source. Equipped with a plasma torch and a suspended tungsten electrode, these robots compress the arc, creating high-speed plasma flow. They are known for their precise welds and short cycle times, making them ideal for preventing part distortion and ensuring optimal weld quality.
These different types of welding robots offer a range of capabilities and applications, each specializing in specific welding processes and materials.
The Future Of Robot And Cobot Welding
The welding industry is witnessing rapid evolution, with the emergence of robot and cobot welding technologies offering significant benefits to small and medium-sized businesses. As advancements in technology continue, the future of robot and cobot welding appears promising.
Ongoing developments in robotics and automation present opportunities for small and medium-sized welding businesses to enhance their operations through the implementation of robot welding systems. These systems offer increased speed, productivity, and reduced welding costs per unit, leading to significant efficiency gains for companies.
Moreover, the continuous improvement in robot designs, control, and mobility ensures that robot welding systems remain reliable and cost-effective throughout their lifespan. The collaborative nature of welding cobots is expected to drive their demand, as they can work closely with human operators, enhancing the flexibility and adaptability of welding processes.
In conclusion, robotic welding technology has revolutionized the welding industry by boosting productivity, reducing costs, and improving weld quality. Its indispensable role in various manufacturing processes has made it an invaluable tool. Through ongoing advancements in design, control, and mobility, the future of robot and cobot welding holds immense potential, promising further automation benefits and efficiency gains for businesses in the welding industry.
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Frequently Asked Questions
How does an automatic welding machine work?
An automatic welding machine works by feeding a linear welding electrode, commonly known as wire, from a spool. This wire is typically a seamless mild steel pipe filled with flux. The flux plays a crucial role in ensuring the quality of the weldment. As the machine operates, the wire is continuously fed through the welding torch. The flux, which is internally filled in the wire, aids in shielding the welding area from contaminants and atmospheric gases, while also serving as a cleaning agent. This process creates a high-quality weld that is both strong and durable.
How does a spot welding robot work?
A spot welding robot operates by utilizing high-current electricity to create intense heat in a localized area on the workpiece. This heat causes the metal to reach an extremely high temperature, enabling it to soften and ultimately fuse the two pieces together. The robot applies pressure to ensure that the two metal pieces are held tightly together during the welding process, resulting in a strong and secure bond. By precisely controlling the application of heat and pressure, the spot welding robot allows for accurate and efficient welding of metal components.
Why do we need robots in welding?
Robots play a crucial role in welding due to their ability to enhance productivity and accuracy. By utilizing robotic welding systems, companies are able to significantly increase their output speed. Moreover, these systems execute tasks with utmost precision, eliminating the need for repetitive work that can be time-consuming. Unlike manual welding that heavily relies on human laborers who require breaks, vacations, and are susceptible to sick days, robots operate tirelessly without any interruption, thereby ensuring a consistent workflow.
The incorporation of robots in welding offers numerous advantages. With heightened productivity, businesses can fulfill customer demands and project deadlines more efficiently. Additionally, the ability of robotic systems to execute welding tasks with high accuracy minimizes the occurrence of errors and flaws, resulting in enhanced product quality. By eliminating the need for human laborers to repetitively perform tasks, companies also reduce the risk of injuries and occupational hazards associated with manual welding. Overall, the integration of robots in welding processes optimizes efficiency and safety, making them a valuable asset in modern industrial operations.
How does a welding system work?
A welding system operates by harnessing high temperatures to fuse two or more workpieces together. When the welding process begins, the intense heat generates a molten weld pool. As this pool cools down, it solidifies, effectively merging the workpieces into one durable unit. It is fascinating to note that the resulting weld can possess even greater strength than the original parent metals, establishing a robust and long-lasting bond.
