How Robotic Welding Works
Welding robots have always been an essential part of manufacturing and fabrication processes. They are typically employed for welding large, heavy parts in sectors such as automotive or aerospace industry among others; this is where they can be most useful because it may not always feasible to hire human welders for these types jobs.
Robotic Welding Processes
Robotic welding can be used to join the following materials: steel, stainless steel, aluminum, copper, brass, cadmium, aluminum alloys, copper alloys, stainless steel alloys, polymers, light metals and nonferrous metals like titanium, zirconium, niobium, tantalum, tungsten, molybdenum and others. In fact, the robotic arm can perform welding on any material you can imagine.
This automated process also uses an electronic torch and a nozzle to deliver filler wire to the weld. This wire comes in several types. Its composition, for example, is aluminum or stainless steel. The wire comes in different diameters, sizes, and lengths for any project. With the help of a robotic arm, the operator can weld at a fast speed. Larger projects that would take several man hours to complete can be done in days. The process is automated and controlled by the robot controller.
Arc Welding In Robotics
Arc welding is most commonly done with a welding rod, which is made of a mixture of metal and filler. The welding rod is fed into an arc between the workpiece and the welding rod. The filler wire is fed into the arc, which enables the welding process to occur. Arc welding can be done with either a stick or wire feeder. The stick welding uses a rod and feeder to create the weld.
The process requires a constant flux to keep the arc going. The wire feeder gets the filler wire from a reel. The operator controls the welding rod with a stick. This makes the process more efficient because it is less likely to skip a spot. The arc produces high heat, which melts the metal and creates the weld. Arc welding often requires a lot of human supervision. The welding rod usually requires frequent cleaning, which is a task not suitable for humans.
Robotic Welding Machine
Spot Welding Robot
Spot welding is a repetitive process. This means that welds are produced over and over again. For example, automotive body parts often require spot welding for a manufacturer. The process creates a line of welds that may be as close as an inch apart. Spot welding can be used for highly precise welding applications, making it the perfect service for manufacturing plants and automotive repair shops.
Arc Welding Robot
his welding process is used when more than one type of metal is involved. In this process, the heat of an arc melts the metal in the weld. The filler wire is then fed into the melted area to fill it in. The wire is melted along with the metal at the weld site. The result is a solidified joint that better resists corrosion and other wear. Resistance is typically used for metals that are hard or brittle, such as stainless steel.
Robotic vs. Manual Welding
Manual welding is the traditional method of metal joining. It requires a large degree of physical effort and the appropriate level of skill to complete a project.
For example, a first-time manual welder is unlikely to be able to assemble a large metal structure without causing damage to the parts. The process requires that the operator pay special attention to each component as the metal connects. Manual welding is a time-consuming process, taking several hours to complete a project.
In contrast, a robotic welder will be able to complete a project in a fraction of the time. This speed and efficiency allows the robot to connect each part quickly without causing damage to the parts.
Between the two methods, robotic welding offers the most benefits. A welder with the right training can complete a project in less time and with higher accuracy. The robotic process also reduces the risk of injury, allowing for safer welding operations.How Robotic Welding Works
The Future of Robotic Welding
With the added benefits of safety, efficiency and accuracy, more companies will likely use robotic welders in the near future. Unfortunately, some drawbacks of the technology will make it hard to use for smaller projects. For the time being, companies looking to use robotic welders will need to consider their timelines and overhead costs.