Welding Robots-How They Work and Are Programmed
There has been a long-standing debate as to whether collaborative robots are
able to integrate well into all areas that are currently being welded manually.
The truth is, the use of robots in welding is on the rise.
Robotic welding mechanizes welding, thereby increasing accuracy, reducing time
spend welding and enhancing safety. All the benefits of welding robots have made
robots a preferred alternative to the manual joining of metals. Several
industries have jumped on the automated welding bandwagon to get results as fast
as possible.
The Process of Robotic Welding
Welding, whether done manually or with the assistance of a robot, requires high levels of skills and education. However, it is unfortunate that the number of professional welders currently available doesn?t meet the industry's needs. According to the AWS, the welding industry is set to experience a shortage of about 45,000 welders by 2022. The good news is that robots can pick up and fill in that shortage. The process of welding these robots give undergo as follows;
1. Arc welding
This is a standard welding process where an electric arc generates extreme heat. The heat can reach up to 6,500 degrees to be able to melt metal. The molten metal is used to join parts together, solidifying into one stable connection after cooling down. If the welding project demands accurately adjoined metals, this is the ideal application to use.
2. Resistance Welding
If a welding project requires cost reduction or heat treatment, resistance welding is the proper process. In resistance welding, molten metal is created using current electricity as it goes through two metals. The molten metal is then used to join metal pieces together.
3. Spot Welding
Some materials are resistible to electric current, especially in the automotive industry when piecing together automobile body parts. A resistance welding variation is used to connect the single spot to thin sheets made from metal to overcome such a situation.
4. Tig Welding
Also known as the GTAW or tungsten arc welding, this is used in situations that call for high precision levels. Here, there is an electric arc that moves between the metal base and the tungsten electrode.
5. Mig Welding
Also known as MIG or GMAW (Gas Metal Arc Welding), this is a straightforward and fast welding method that utilizes high deposition levels. The wire continuously moves through the heated welder?s tip. It melts the wire, and the result is large amounts of molten metal dripping to the base. This molten metal is what is used to join the base to other metallic pieces.
6. Laser Welding
If your welding projects require many parts and precision, this is the method is mainly preferred. Laser welding is used in medical components or jewelry.
7. Plasma welding
This method provides a high level of flexibility because its temperature and gas speed can easily change.
Welding Robots-How They Work
When robots are used for any process, the method needs amending to accommodate automation. The same can be said regarding welding, which uses different tools that aren?t included in the manual equivalent. The human workforce does not need programming the same way a welding robot does.
The robot used in welding has an arm that can move in different directions. For example, the rectilinear types have a triple dimension motion-ability. In such a robot, the wire feeder directs the filler wire to the robot for a job. There is also a torch that has a high heat situated at the end of that arm. This torch is the one that is used to melt metal, thus allowing the welding procedure. The welding temperatures have been known to reach thousands of degrees. As such, using this robot keeps your human staff safe from work-related injuries.
Human operators can also operate these welding robots. However, the operators must be certified by AWS (American Welding Society). It gives human operators permission to operate manually and robots? arms when welding.
The robotic arm heats up then it is the one that melts the metal you want to conjoin to another piece. As earlier explained, the wire feeder will deliver more metallic wire to the torch and arm. As you await the next part that needs welding, the arm will automatically move the torch in the direction of the cleaner. It will then clean metal splatters gotten from the robotic arm. Without this cleaning process, the metals could solidify on the torch, thus affecting the arms welding functionality.
One of the primary reasons people purchase this robotic welder is to keep
human workers safe. These machines come incorporated with many different safety
features. The arc shield stops high heat from coming in contact with oxygen. The
areas that are enclosed also keep human workers safe from the bright light and
temperatures.
Advantages of Robotic Welding Robotic welding comes with a variety of positive
attributes like:
- Increased efficiency
- Enhanced safety
- Better accuracy
- Less wastage
- Lower cost of delivery
Robotic welding disadvantages
- The upfront cost is high
- Less flexibility as compared to people.
- It isn't feasible if you have a small project.
Manual Vs. Robotic Welding
Modern manufacturing still has enough room for manual welding. More so, in projects that need a quick style change. Professional welders can change styles with ease, but welding robots cannot. Since manual welding is still needed mainly by most companies, manual welders aren?t disappearing anytime soon.
Replacing human workers with welding robots doesn?t mean that AWS?s certification business will die. On the contrary, robotic welder operators must be in possession that that certification can operate the automatic welders. Having certified experts handling these robots means that the process will be a smooth one and cost-effective.
Conclusion
Implementing the use of robotics when welding is a tough decision. Whatever step you make for your business to create a smoother and more effective process eventually optimizes production. This is especially true in a scenario where there is many personnel who are maintaining the robotic welders. From high-quality welding to better work consistency, using robotics for welding will significantly benefit your business.
