Welding automation offers numerous benefits for companies of all sizes — from improved productivity and weld consistency to lower costs for production, labour and materials.
No longer are robots just suitable for large manufacturers but smaller to medium size businesses also stand to benefit by implementing a Robotic Welding technology solution.
1. Increase in Productivity
With a robots ability to process welded components three to five times faster than humans by operating continuously, withstanding a greater arc on-time and moving quickly between weld joint positions, a robotic welding system can provide substantial increases in output.
2. Consistent and Repeatability
Manual welding requires a high level of skill as well as concentration to achieve consistency and repeatability. A robotic welder can continue to perform precisely the same weld cycle continuously, 24 hours a day, seven days a week.
Manual welding processes require multiple jigs which are swapped out with each production run. Robots can save valuable time and eliminate tool changes as grippers can grab any part regardless of size or shape, position it on the assembly, and hold it tight during the welding process
Numerous safety risks exist for welders such as electric shock, exposure to gases and toxic fumes, and welder’s flash burns to the eyes cornea. Robotic welders have proven themselves in reducing the number of accidents to workers in the metal fabrication industry with the number of injuries reported to Safe Work Australia reducing each year.
A robotic welder can achieve superior quality by ensuring the correct welding angle, speed, and distance with repeatability of accuracy of (+0.04mm). Ensuring that every single welding joint is consistently produced to the highest quality significantly reduces the need for costly rework.
With a shortage of skilled workers, robotic welders have helped to overcome this issue. Whilst manual welders will still be required for jobs which have a high degree of customisation, a robotic welder will alleviate issues in busy times by reducing additional hours and the need to hire and train extra staff.
7. Reduce Consumables
With manual welding, the size of the weld is determined from the operator and could result in a larger weld than required. Robots are programmed to always weld to the correct length and size of the joint requirement, providing significant saving over time.
8. Reduced Production Costs
Through improvements in quality, consistency and productivity a robotic welding system can deliver parts at a reduced cost. Further saving can also be made through reduced energy consumption and consumable costs in addition to lowering workers compensation and insurance costs.
9. Reduction in Weld Distortion
Distortion in a weld occurs from the expansion and contraction of the weld metal and adjacent base metal during the heating and cooling cycle of the welding process. Robotic welders are tuned to correctly size the weld for the requirements of the joint, minimise the amount of weld passes and complete the process with speed to minimising the heating of the surrounding metal that can expand and lead to distortion.
10. Increased Competitive Advantage
Implementing a robotic welding solution can set companies apart from the competition by allowing for faster completion and delivery of products whilst ensuring consistent quality.
Scott has extensive experience in the Metal Fabrication sector and can tailor a robotic welding solution to suit your requirements.
Our experienced team of engineers are always available to implement your solution, tailor preventative maintenance programs to minimise downtime and provide ongoing service and breakdown support.