A Smarter Way to Weld.
As labour shortages continue Worldwide, finding skilled welders is becoming a challenge for many businesses. Welding automation offers a smart solution. Not only does it maintain high production quality and reduce defects. But it also brings long-term benefits that go beyond saving time and labour.
How to Get Started with Welding Automation?
The best approach is to start with simple tasks to gradually improve your production line. Avoid jumping into the most complex processes right away. It's also important to note that automation can't fix issues from your suppliers. So improving upstream processes will ensure you get the most benefit from your automation investment. If you’re unsure where to begin, we have the experience and expertise to guide you. We’ll work with you to find the best solution that fits your production needs and budget.
When to Use Welding Automation.
Many jobs are still suitable for manual welding. For example, if a welding operation is too small to have an automatic welding machine. Or if repairs must be carried out at site. There are also many welds that would benefit from an automated welding process.
Pipe welding in industrial applications (like chemical processing and energy production) need the precision that welding automation offers. Using an orbital welder for example will avoid springing a potentially hazardous leak.
Variations of Automatic Welding
There are two variations of automatic welding. Semi-automated welders use a pre-programmed automatic welding machine. However the parts are loaded onto the welding bench by an operator. They attach to the fixture, then start the weld programme. The finished workpiece is removed manually, and the process is repeated as necessary.
Fully automatic welding removes the human element of the job. An operator will just oversee the operation to ensure there are no faults or errors. In these set-ups, the parts and finished workpieces are moved by other equipment, like a conveyer belt. The welding operation is often continuous over a large number of individual pieces. This is a truly industrial use of the automatic welding machine. Found in very large operations such as car factories, or fabrication shops producing large volumes of components.
Advantages vs Disadvantages
Automatic welding machines have advantages and disadvantages. As with many things, a gain in one place is compensated for by a loss in another.
Advantages
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Consistency & Quality. Delivers repeatable, uniform welds with reduced human error.
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Higher Productivity. Faster welding speeds and less downtime increase throughput.
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Reduced Labour Costs. Fewer skilled welders required per output level.
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Safety Improvements. Operators work at a distance, reducing exposure to fumes, sparks, and heat.
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Precision Control. Ideal for complex weld geometries, small tolerances, and specialised materials.
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Lower Scrap & Rework. Precise control reduces mistakes, saving material and time.
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Scalability. Easy to integrate into production lines for high-volume manufacturing.
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Data & Monitoring. Many modern systems offer digital monitoring, traceability, and process logging for quality assurance.
Disadvantages
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High Initial Cost. Significant capital investment compared to manual welding equipment.
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Specialised Setup. Requires skilled engineers to program, maintain, and operate the system.
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Less Flexibility. Best suited for repetitive tasks; changing jobs or materials may require re-programming and new tooling.
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Maintenance Demands. Downtime for repairs or calibration can halt production.
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Space Requirements. Large footprint compared to manual welding setups.
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Training Needs. Operators and technicians need specific skills to manage automated systems.
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Not Ideal for Low-Volume Jobs. Less cost-effective for small or custom projects.
Automated Welding Equipment Solutions
Full or semi-automatic welding systems come in many shapes and sizes. Able to undertake a variety of applications from welding pipe to ship building. Common components include:
Column & Boom Manipulators
To meet the stringent requirements of aerospace or nuclear related applications column and boom manipulators need to provide exceptional rigidity. As well as low deflection under load and smoothness and consistency of axis movement. To meet these demands, features like high-quality sub components and stress relieved fabrications are key. Providing industry-leading stability and minimal boom deflection. Plus lack of vibration at full boom extension.
Light duty and standard models are generally better suited to precision engineering applications. Look for precision boom drive (for linear welding applications) or even precision column drive (vertical. Utilising recirculating, ball-screw type mechanisms.
All column and boom manipulators, X & Y motions can be via precision bearings and guide ways. Design features include thick section fabrications that have been stress relieved. Ensuring the highest standards of straightness and dimensional tolerance. Applicable weld processes for precision applications include TIG and plasma welding. MIG/MAG is also possible, processes where high-level weld head payload is not a primary factor.
Heavy duty column and boom welders share the same design features as precision manipulators. So they also can be used in a similar way. However, these units are built for industrial MIG/MAG and submerged arc (SAW) processes. A range of optional extras including powered carts and king pin rotation of the column improve production efficiency.
All column and boom manipulators work with a range of controls. Depending on size and duty, boom motion control may be via a frequency inverter type drive with encoder feedback.
Factory space an important consideration? We can offer models featuring telescoping of the boom, minimising space requirements to the rear. Movement of the telescoping sections is synchronous. Helping to ensure the highest possible smoothness of motion is maintained.
Brands of Column and Boom welders we recommend are:
Seam Welders
Longitudinal seam welders are utilised in manufacturing cylinders in a wide range of thickness and length. Applications range from the seam welding of small diameter tubes with short length and ultra thin wall thickness. (like bellows and instrument manufacture). Through to large diameter beverage and brewing tanks, and thick wall pressure vessels.
Seam welders can be used with a number of welding processes. TIG and plasma tig welding are ideal for use where precision and weld aesthetics are important. Or for thin material. For speed, efficiency, or thicker material, MIG and sub arc are the preferred choice.
Get in touch with our team if you need assistance and advice on choosing the right machine and application for your project.
Commercial sectors and industries that seam welders excel in include aerospace, HVAC, and pressure vessel fabrication. As well as utilities and dairy, food and beverage processing.
Brands of Seam welders we recommend include:
Welding Lathes
Lathe welders are a circumferential welding soluton. Compact systems are ideal for small components such as bellows, sensors and transducers. Or larger models offer consistency for welding larger components like hot water tanks and fuel containers. As well as nuclear waste containment and food and beverage containers.
For small to medium size components, we offer our New Pro-Arc lathe range. These modular units feature ultra-low backlash, harmonic type gearboxes, and encoder servo motor drive. Options for bench or freestanding models, as well as controls suited to the most demanding precision application. Typical weld processes include Micro TIG, Micro plasma, TIG, Plasma and MIG. Suitable for applications like air cylinders, valve assemblies, catalytic converters and hydraulic actuators.
Larger circumferential welding lathes can accommodate diameters up to 1500mm and weights up to 10,000Kgs. Generally used for dished ends on large cans and towers. As well as tanks, boilers and reactors. Various control options are possible including PLC for maximum performance. Welding process selection would be TIG, plasma, MIG or sub arc, depending on material thickness.
Brands of lathe welders we recommend include:
Industries utilising welding lathe technologies include aerospace, instrument and transducer fabrication and pressure vessels. As well as tanks, boilers and reactors in industries like power generation, shipbuilding, and utilities.
Robotic Welding Equipment
There are two types of industrial welding robots; articulating robots and rectilinear robots. Robotics control the movement of a rotating wrist in space.
Rectilinear robots move in line in any of three axes (X, Y, Z). In addition to linear movement of the robot along axes, there is a wrist attached to the robot to allow rotational movement. This creates a robotic working zone that is box shaped. Articulating robots employ arms and rotating joints. These robots move like a human arm with a rotating wrist at the end. This creates an irregularly shaped robotic working zone.
There are many factors that need to be considered when setting up a robotic welding facility. Robotic welding needs to be engineered differently than manual welding. A robotic welding system may offer a more repeatable solution vs manual welding. However, robots may necessitate regular re-calibration or reprogramming.
Robots should have the number of axes necessary to permit the proper range of motion. The robot arm should be able to approach the work from multiple angles. Robotic welders are able to operate continuously, provided appropriate maintenance procedures are adhered to. Continuous production line interruptions can be minimised with proper design and maintenance. Planning for the following contingencies needs to be completed:
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Rapid substitution of the inoperable robots.
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Installing backup robots in the production line
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Re-distributing the welding of broken robots to functioning robots close by
Brands of Robotic welders include Motoman, OTC, Kuka, ABB, Fanuc, Panasonic, Miller, Lincoln
Benefits of robotic weldingProductivity
A robot typically works between two or more work stations. This means that during the welding cycle, the operator is unloading and re-loading components to a welding fixture. Because there is less handling compared to a manual weld cycle, the robot achieves much higher levels of arc-on time.
The robot also moves very quickly between the joints and this yields a further saving in cycle time. Typically a robot system will increase output by a factor of two to four. This depends on the nature of welding. An assembly with lots of short welds can be produced with the most time savings.
The cost savings that robot welding brings can help companies to be more competitive. Bringing them more in-line with imported products. To assess productivity improvements, it's recommended to compare manual welding times with robot welding times.
Quality
The robot has a very high repeatable accuracy (± 0.08 mm) and excellent path following accuracy. Presenting the welding gun at the correct welding angle, welding speed and distance. The high level of integration to the welding equipment ensures that optimum conditions can be used for every joint. The end result is consistent high quality output, day in day out, year in year. With reduced cost for re-work, scrap or removal of weld splatter.
Consumable costs
It is up to the judgment of a manual welder to weld to the correct standard, but often the weld is oversize. A robot however, always welds to the correct length and size of weld that it has been programmed to produce. This means that some potential savings in wire consumption can be made. If for example a manual welder welds a 5 mm fillet, where only a 4 mm fillet is required, the savings in welding wire alone will be a staggering 36%!
Labour
In recent years it has become increasingly difficult to employ manual welders. Staff turnover is often unavoidable, carrying costs for recruitment and training. When labour is an issue, companies often find themselves working overtime. Or having to employ additional contract labour to meet demands; having a serious impact on production costs. If products cannot be supplied to the end customer, penalties may be incurred or future business may be at risk. There will always be a need for manual welding. Those companies investing in robotic welding for production tasks reduce the disadvantages.
Safety
A robotic welding system can help to eliminate health and safety issues associated with welding. Including hazardous welding fumes and exposure to arc-flash. Reducing the risk of employee compensation claims for hazardous working environments.
Flexibility
The robot can be used to weld many different products and allows companies to consider Just In Time production. Reducing Work in Progress and stock levels can lead to savings in labour, transport and storage costs for unused products.
Floor space
Compared to the same output from manual welding bays, a robotic welding cell needs less floor space.
Would you like to talk to our Team?
Maybe you are not sure which welding machine is best for you? Our Sales Team is more than happy to discuss your welding requirements.
With extensive knowledge on ALL makes and models, they can suggest the most suitable machine for your application and budget.
Between Monday and Friday during our working day of 8am – 5pm GMT, we aim to reply to your request within 2 hours of receiving your email.