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  1. Welding Automation in the Automotive Industry

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    welding robot in the automotive parts industryWelding automation is the process by which technology, instead of human labor, is used to join materials together, resulting in a process that is safer, faster, higher quality, and more efficient than manual labor. Welding automation typically uses robots, but can also use a servo with the same X, Y, Z coordinates used in programming robots to increase the performance of production welds. These two systems can reduce the chances of errors or inconsistencies occurring in manual welding processes. Because these robots or servos are computer-based, they can be programmed to smoothly and precisely follow a specific path along a seam and make corrections as needed. Overall, although welding is an incredibly complex manufacturing process, automated welding can dramatically increase the productivity, quality, and profitability of many processes — especially those in the automotive industry.

    Welding Automation In Automotive Manufacturing

    Typically, a welding automation setup involves the use of several different types of robots. Large robots are commonly used to handle spot welding on heavy car body panels due to their long arms and high payload capabilities. In contrast, smaller robots can weld lighter parts, such as mounts and brackets. Robotic MIG and TIG welders are also commonly used because they can position their torches in the same orientation every cycle. Because these robots have repeatable arc and speed gaps, they can meet high welding standards.

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    Advantages of Welding Automation in The Automotive Industry

    Welding automation strategically integrates technology into your welding process. Some of the main advantages of welding automation include the following:

    Safety

    Robotic and servo welders can dramatically increase the safety of any automotive workshop. Not only do they remove humans from hazardous situations where they might be exposed to chemicals, fumes, extreme heat and noise, and weld flash, but they can even keep humans safer and healthier by limiting their chances of experiencing musculoskeletal stress caused by lifting or twisting. Additionally, because robotic and servo welders can perform dangerous tasks such as crash tests, they can help keep future consumers safe.

    Quality

    While human welders may be skilled, welding automation technology is far more efficient. Automated equipment is capable of completing jobs more quickly and consistently than manual laborers, and they’re even able to meet industry standards within tight time constraints and without any delays. Additionally, welding automation equipment can produce tighter welds and perform highly intricate tasks, thus making them more efficient than human welders and able to keep up with changes in automotive industry standards.

    Delivery

    Welding automation can also be used to help manufacturers reduce waste. Welding automation can lead to process regulation with greater control and faster travel speeds; additionally, they can reduce the non-welding time and waste associated with it caused by humans. Overall, welding automation is efficient and generates fewer waste materials, leaving you with higher-quality welds created using fewer resources.

    Cost

    Staffing and training welding technicians takes time and money. In contrast, welding automation does not require training, which can help you save time and money. Many automotive companies have been able to save millions of dollars by embracing robotic and servo welders that increased their production. The cost-effectiveness of welding automation goes beyond the assembly line: companies can even save additional money with welding automation because they do not require salaries, benefits, or sick days.

     

    An infographic depicting the advantages of welding in the automotive industry

    Automobile plant, welding process, modern production of cars, robot equipment, automated production line.

    Tec-Option: Your Partner and Expert for All Welding Automation Needs

    Welding automation is a useful way to improve the quality of your welds while also saving money, reducing waste, improving the safety of your workshop, and meet the deliveries required by today’s markets. If you’re interested in learning more about welding automation, contact Tec-Option Automated Welding Systems today. Our experienced team is excited to help you see the benefits of robotic welding technology in the automotive industry for yourself.

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  2. Setting Up a Preventive Maintenance Plan: Key Factors to Consider

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    Quicker Setup on Your Floor Gets the Product Out the DoorPreventive maintenance is essential to the productivity and lifespan of your automation equipment. From inspecting and cleaning components to replacing, tightening, or lubricating parts, preventive maintenance helps you correct small issues before they lead to costly equipment failures.

    To properly set up the best preventive maintenance plan for your equipment, follow the steps below.

    Determine Who Will Be Involved

    It is important to determine who will be involved in the preventive maintenance procedures before organizing your maintenance plan. Including top management, maintenance managers, and other experienced equipment operators will ensure that everything runs smoothly and that you receive proper feedback.

    Set Goals for the Preventive Maintenance Plan

    With input from your preventive maintenance task force, it is important to set measurable goals that can be tracked, improved, and achieved. By looking at your system metrics, you can determine areas for improvement and track your progress towards your desired goals.

    Inventory the Facility Equipment and Assets

    Create a master list of all the equipment you intend to include in your maintenance plan with specific details about that equipment. This will help you design your maintenance schedule, determine where your challenges may lie, identify the most costly equipment, and make it easy to order replacement parts quickly.

    Include the following information:

    • Make, model, and category of the equipment
    • Serial numbers and other identification numbers
    • The location of the equipment in your facility
    • What the equipment does
    • The department and team leaders who are responsible for the item
    • Any specific costs associated with that piece of equipment
    • The age of the equipment, its current condition, and its priority level within your facility

    Create Preventive Maintenance Procedures

    Determine what kind of maintenance is required for each piece of equipment based on the operator’s manual, the manufacturer’s recommendations, and any past corrective actions you’ve taken. You should also determine how often these tasks should be performed and how long it will take to perform them. Depending on the machine, different factors determine when preventive maintenance needs to be performed, including the number of operating hours, the number of items produced, or other meter-based triggers.

    Develop Preventive Maintenance Schedules

    It’s important to streamline your preventive maintenance processes to make the best use of your time, money, energy, and resources. It is best to schedule high-priority preventative maintenance first, which can be determined by evaluating the goals you listed before. It is also important to leave space for unexpected situations such as emergency repairs.

    Robotics equipment on a shop floorTrain Your Team

    Your maintenance technicians should be thoroughly trained in proper inspection and care of each machine. They should also understand the benefits of performing ongoing preventive maintenance, so they don’t become complacent with their preventive actions. Anyone who operates the machines should be instructed in the daily maintenance procedures and inspections that help ensure operator safety as well as prolonged equipment life.

    Analyze, Correct, Improve

    It is important to revisit your preventive maintenance plan every couple of years and make adjustments to ensure that it’s the most effective plan for your equipment. Continued attention and detailed records of your maintenance plan will make it easier to implement new maintenance plans in the future.

    An infographic showing the steps of how to set up a preventive maintenance plan

    Preventive Maintenance from Tec-Option

    At Tec-Option, we have experience working on the most challenging automation systems. Contact us today for help optimizing cycle times, boosting productivity, and increasing reliability with our proper system maintenance, calibration and retooling services.

     

  4. One question always asked of Tec-Option

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    There is one question that is always asked of Tec-Option,

    “Can you perform different types of welds in the same machine?

    Projection Spot WeldThis is an excellent question for there are several types of welds used within the industry and each has its specific function. Spot welding is the most common and used for many types of assemblies. But there is also projection welding which adheres a nut or threaded stud to an assembly. There is also MIG welding (metal inert gas) that is common for stronger weld applications. Lastly there is a weld type known as drawn arc weld and that is used for more specific applications.

    Most Weld Machine builders focus on one type of weld when building for that is generally all that is required. But there are instances when you need more than one process. What if your assembly requires a nut and also spot welds? That usually means building more than one machine to meet those needs. Here at Tec-Option we have incorporated two and even sometimes three different weld types or operations into one machine. So yes, it is possible to weld different types of welds in one machine.