The automotive and transportation industries have been using advanced technological innovations to improve their productivity. Automated robotic welding systems are among the most important components in the operations of these industries. The rising demand for automobiles worldwide has put pressure on automotive companies to increase production. This means investing in more efficient machines like robotic welding machines.
EVS offers automated welding processes to help enhance safety as well as increase the accuracy and speed of the automobile manufacturing process. Our welding robots ensure that you complete your projects on time. Various robotic welding companies have also been using our automated systems to get quick results. You can contact our experts if you want to streamline your welding processes.
Welding is a process that joins two materials by applying pressure and heat. Automated welding, also known as robotic welding, is the process of automating welding tasks using programmable devices (robotic welding machines) to weld parts.
Robotic welding machines are made through the combination of artificial intelligence, control systems, sensor technology, robotics, and, of course, welding. The increasing demand for improved flexibility, productivity, and quality has led to modern developments to achieve precise control of robotic welding tasks.
Integrating sensing technologies into robotic welding machines allow these machines to achieve the desired control level of the operator. Robotic welders use sensors to measure and observe process parameters. They act as input sources to the robot’s control system. By analyzing the input from the sensors, the robot can perform tasks according to the defined welding specifications.
Robot welding cells, also called robot welding units, consist of various components that work together to weld parts. These components consist of the main welding devices, including safety features and accessories, that ensure the cell’s smooth operation. The main component of a robotic welding cell is the welding robot which includes the end effector or welding manipulator (usually a torch).
A welding manipulator moves the weld head closer to the object being weld. It extends the working range of the welding robot as well as its accessibility when welding large and complex geometries. Its control is often synchronized with that of the welding robot to achieve greater accuracy.
Below is an overview of how robot welding cells work:
If you want to automate your production line’s welding processes, EVS offers reliable robotic welding cells for sale.
Although the cost of welding robots can be quite overwhelming in the beginning, they provide a lot of advantages that have convinced various businesses to invest in these machines. A few of these advantages are the following:
Robots can finish tasks with higher accuracy compared to human workers, regardless of how experienced the workers are. Robots can maintain the same accuracy level until the completion of the project.
Robot welders are equipped with various safety features that help in protecting human workers from the dangers in the working environment. A safer workplace can increase the productivity of the workers.
Robots do not need to take a break or time off. They can continuously operate 24 hours a day. With quicker speeds and longer operation hours, robot welders can complete their tasks much faster.
Upfront costs of using robotic welders can be high but once they are installed, their high productivity will eventually cover up the loss. Moreover, automatic welders have high production levels so they cost less compared to employing multiple human workers.
The high precision and accuracy of robotic welders reduce the waste generated because of mistakes. This allows a more efficient manufacturing line.
Basic automated robotic welding systems are composed of 2 subsystems:
Normally, 6-axis robots consisting of a 3-axis wrist and a 3-axis arm are used because you can mount the torch at their wrists for more flexibility. This makes 3-dimensional welding easier.
General-purpose robots for industrial purposes that use welding torches as manipulators are traditionally used for automated welding systems. However, many industrial robot manufacturers have started to develop robots that are specific to a welding application which we will discuss in the next section. These application-specific robots are less expensive. Thus, reducing initial investments and increasing the demand for automated welding systems.
Below are the common applications of robotic welding machines:
MIG welding robots are used in gas metal arc welding applications. MIG welding is a straightforward process that employs a high deposition level. MIG welders can join a wide variety of metals with different thicknesses.
For applications that require high precision levels, TIG welders are more suitable. TIG welding is used to weld fenders, door handles, lawnmowers, bike frames, wagons, and others.
Also called resistance spot welding, spot welding is primarily used to weld more than 2 metal sheets together. The welding process is done through the application of heat and pressure obtained from an electric current to the weld area.
This is the most common type of welding where a high-current electric arc serves as the heat source to melt the metal. Arc welding robots join 2 parts together through the molten metal which solidifies into a strong connection after it cools.