Innovation in technology has led to significant advancements in automated welding techniques. Automated welding, including robotic welding, provides many valuable benefits such as increased accuracy and safety, as well as a reduction in project time. Many industries consider automated welding to be essential to their operations. The transportation and automotive sectors in particular welcome technological advances in welding as a key method of improving productivity, and the number of companies adopting automated welding solutions is constantly growing.
What is Automated Welding?
Automated welding is a general term that encompasses several welding processes that use equipment capable of running without an operator. Automated welding machines use computer programs to weld materials in a way that minimizes processing time and improves production efficiency. Robot welding is a type of automated welding that is used to perform complicated welds using a robotic arm with multiple axes.
Automated vs. Manual Welding
While both automated and manual welding join separate materials using heat and pressure, there are certain situations where one method is preferable over the other. Manual welding is optimal for projects where several styles of welding need to be used in quick succession. An expert welder can change welding styles and adapt to uncertain situations more easily than a robot. Manual welding also requires a worker to load and unload the workpiece.
Automated welding, however, is performed by robots without the need for manual intervention. Robotic welding processes are completed faster than manual techniques and can deliver high outputs that are extremely accurate. Both manual and automatic welding require professional welders, as robot welder operators are needed to program the robots. Most robot weld operators are required to obtain a professional certification to ensure their correct understanding of how to program the machines and finish projects cost-effectively and quickly.
The Automated Welding Process
In automated welding, a robot capable of moving in all three dimensions is used to perform all aspects of the welding process, from positioning the materials to completing the weld itself and even cleaning. There are several types of robots to choose from, including rectilinear and articulating models. Each offers varying degrees of movement control.
All robot types feature a wire feeder that delivers wire filler to the area where the weld is being created. The end of the robot’s arm contains a torch capable of generating thousands of degrees of heat. The robot positions the wire filler in place and then melts it to create the weld. If metal splatters during this process, the robot can be programmed to detect this and promptly clean it before it solidifies. It can even clean metal from its own arms.
Certified human operators play an essential role in the automated welding process. The American Welding Society offers certifications in manual welding as well as robotic arm welding operation. Robotic welding arm operators learn how to teach the automated system to move the arm, how to change system parameters, and how to program the welding arm to perform various processes. During the actual welding, humans can be separated from the process, ensuring their safety.
Advantages of Automated Welding
When choosing whether to adopt an automated welding system, there are several key advantages to be aware of:
Adaptability
Robotic welding systems use grippers that can handle parts of any size or shape and hold them securely while performing the welding process. This significantly reduces the time normally spent changing tools.
Limiting Weld Distortions
Robotic welders are extremely efficient and programmed to correctly size welds based on joint requirements. This minimizes the number of required weld passes, reducing the time metals are exposed to heat and thereby decreasing the likelihood of distortions occurring.
Lower Labor Costs
Automated welding processes reduce the need for human labor, which is one of the most expensive factors of production. Although semi-automated processes still require some manual labor, it is significantly less compared to manual processes.
Lower Risk of Injury
Human workers are kept at a safe distance in robotic welding operations. Since operators don't need to be present for the actual weld process, the risk of worker injury significantly decreases.
Increased Productivity
Robots are significantly more efficient than human workers at welding tasks, which allows for components to be processed quickly. They can also work continuously and have higher arc on-time percentages than human welders.
Reduced Sizing Errors
Robot welders are programmed to select the ideal joint dimensions for each job so that no weld is larger than necessary. This provides significant savings in time and materials.
Repeatability
Unlike manual welders which need to be highly skilled to replicate desired results, robotic welders perform the same weld continuously. Robots can perform the same actions for as long as necessary, with repeatable results.
Automated Welding Applications
Due to its highly adaptable nature, automated welding technology has been adopted by companies of all sizes. The benefits in cost, weld quality, and worker safety have caused it to become essential for many industries, including:
Defense & aerospace
Automotive
Amusement
Battery & energy
Construction
Consumer products
E-commerce & packaging
Food & beverage
Heavy equipment
Life sciences
In addition to these industries, automated welding is used in a variety of diverse applications, such as:
The assembly of frames, bodies, and car and motorbike parts
Pipes and tanks
Electronic printed circuit boards (PCBs)
Electrical components
The outer panels and floor materials of trains, cars, and, planes
Cooling equipment valves and pipes
The Different Automated Welding Methods
There are several types of automated welding methods, each with advantages that suit a wide range of applications. Tec-Option provides solutions for the following welding methods:
Projection welding
This form of resistance welding uses pressure and electrical current to form high-strength welds efficiently, with a lower energy requirement. Projection welding requires small points of contact to be built into the design to concentrate the welding current. This welding method provides a close weld with a clean finish, delivers a long life expectancy, and can be performed on multiple areas simultaneously.
The most common type of resistance welding, spot welding generates heat by passing an electrical current through electrodes that are attached to separate metal surfaces pressed together. This technique is used on thinner workpieces than those used with projection welding and is highly suited to automation processes. Welds are performed quickly and easily, with low material costs and safer working conditions as an open flame is not required.
Metal inert gas (MIG) welding is performed by feeding a solid metal electrode through a welding gun to join metal pieces. Also referred to as gas metal arc welding (GMAW), this process is highly precise and accurate and can be performed by a robotic welding operation. MIG welding equipment generally costs less than other methods and is suitable for a wide range of materials. The welds produced typically require no post-processing and are completed quickly.
This process joins base metals to fasteners quickly using a controlled electric arc process to melt the fastener. Because drawn arc welding tools create a concentrated heat, the weld produced is highly accurate. This process is used with aluminum, steel, and stainless steel and delivers high-quality welds that are very strong and look clean and finished.
There are several types of automated welding methods, each with advantages that suit a wide range of applications. Tec-Option provides solutions for the following welding methods:
This form of resistance welding uses pressure and electrical current to form high-strength welds efficiently, with a lower energy requirement. Projection welding requires small points of contact to be built into the design to concentrate the welding current. This welding method provides a close weld with a clean finish, delivers a long life expectancy, and can be performed on multiple areas simultaneously.
The most common type of resistance welding, spot welding generates heat by passing an electrical current through electrodes that are attached to separate metal surfaces pressed together. This technique is used on thinner workpieces than those used with projection welding and is highly suited to automation processes. Welds are performed quickly and easily, with low material costs and safer working conditions as an open flame is not required.
Metal inert gas (MIG) welding is performed by feeding a solid metal electrode through a welding gun to join metal pieces. Also referred to as gas metal arc welding (GMAW), this process is highly precise and accurate and can be performed by a robotic welding operation. MIG welding equipment generally costs less than other methods and is suitable for a wide range of materials. The welds produced typically require no post-processing and are completed quickly.
This process joins base metals to fasteners quickly using a controlled electric arc process to melt the fastener. Because drawn arc welding tools create a concentrated heat, the weld produced is highly accurate. This process is used with aluminum, steel, and stainless steel and delivers high-quality welds that are very strong and look clean and finished.
Why Partner with Tec-Option for Automated Welding Services
As an industry leader in flexible, modular automated welding systems, Tec-Option provides lean manufacturing advantages and utilizes one common machine style capable of performing multiple processes. Our systems streamline the welding process, using robots to reduce errors; increase production capability; and create consistent, high-quality welds. Our robotic welding technology helps you achieve faster turnaround times while producing less waste material.
The automated welding systems from Tec-Option offer a superior design suitable for a range of applications and take up minimal space in your facility. They also feature centralized work cell power distribution and interchangeable tooling that can be performed by an operator with any skill level.
Our versatile systems are designed to do it all and can switch processes in a matter of minutes, with no additional skill required. If you deal with components that vary in style or require multiple processes, Tec-Option automated welding systems deliver the flexibility you need to improve your capabilities.
