Choosing Robotic Welding Process and Equipment

 

In today's competitive manufacturing landscape, precision, efficiency, and consistency are paramount for success. Robotic welding has transitioned from cutting-edge technology to industry standard across businesses of all sizes. The automated and robotic welding sector, including accessories, reached an impressive $1.9 billion valuation in 2017 and continues to grow exponentially. Many manufacturers who once hesitated to adopt this technology are now embracing automated welding systems for their numerous advantages.

For companies considering robotic welding implementation for the first time, navigating the selection process can feel overwhelming. This comprehensive guide will help you understand the various robotic welding processes, equipment options, and how to determine the optimal solution for your specific manufacturing needs.

 

 

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Table of Contents

• Key Considerations When Selecting Robotic Welding Systems

• Types of Robotic Welding Processes

• The Substantial Benefits of Robotic Welding

• Yaskawa's Advanced Robotic Welding Solutions

• Making the Transition to Robotic Welding

 

 

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Key Considerations When Selecting Robotic Welding Systems 

Before investing in robotic welding technology, it's essential to carefully evaluate several critical factors to ensure you select the optimal solution for your specific requirements:

• Workpiece Characteristics:

  • What types of materials are being welded?

  • What are the dimensions and geometric complexities of your parts?

  • Are there significant variations in the parts being produced?

• Precision Requirements:

  • What level of weld quality and consistency is needed for your application?

  • Are there specific industry standards or certifications that must be met?

  • How critical is seam tracking and adaptive welding capability?

• Return on Investment Analysis:

  • What production volumes will justify the automation investment?

  • How will robotic welding impact overall manufacturing efficiency?

  • What is the anticipated payback period for the robotic system?

• System Configuration Options:

  • Would an all-in-one welding cell or a customised, application-specific robot better serve your needs?

  • What peripheral equipment (positioners, fixtures, safety systems) will be required?

  • Is modularity and future expandability important for your operation?

Our experienced team of robotic welding specialists is available to guide you through this crucial decision-making process, analysing your specific production requirements and recommending the optimal configuration for your operation.

Our portfolio includes specialised robotic welding applications designed for various industries and materials.

 

Types of Robotic Welding Processes 

While robotic welding encompasses numerous processes, two predominant technologies have become foundational across major manufacturing industries:

Arc Welding Robots

Arc welding utilizes concentrated heat generated by an electric arc to fuse metal materials together. Though effective when performed manually, this process demands exceptional skill levels that are increasingly difficult to find in today's workforce. Robotic arc welding systems effectively address this skills gap while delivering numerous advantages:

• Consistent Weld Quality: Robots maintain precise control over welding parameters throughout the entire production run

• Reduced Distortion: Optimized heat input and welding sequence minimizes part warping

• Accelerated Production: Shorter cycle times and continuous operation increase throughput

• Programming Efficiency: Advanced offline programming tools reduce setup time between jobs

• Flexible Implementation: Options for jigless welding and reconfigurable systems enhance adaptability

Yaskawa MOTOMAN's specialised arc welding robots deliver these benefits while offering industry-leading reliability and performance. The result is dramatically increased productivity with significantly fewer defects and rework requirements.

Our advanced arc welding robotics systems deliver precision and consistency that manual welding simply cannot match.

 

Spot Welding Robots

For applications involving thin materials where continuous seams aren't required, spot welding provides an efficient joining solution. Industrial spot welding guns often weigh over 100 kg—far beyond human handling capacity—making robots essential for this process. Key advantages include:

• Precise Gun Positioning: Robots position heavy welding guns with exceptional accuracy and repeatability

• Optimal Process Control: Consistent pressure, current delivery, and dwell time ensure weld integrity

• Rapid Cycle Times: Robots minimize non-productive movements between weld locations

• Extended Tool Life: Programmed maintenance positions and controlled movements reduce equipment wear

• Improved Ergonomics: Elimination of manual handling of heavy welding equipment enhances workplace safety

 

Yaskawa MOTOMAN's spot welding robots provide precise positioning with unmatched speed and accuracy, significantly increasing productivity by reducing critical seconds in welding cycle times.

For manufacturers in automotive and other industries, our servo-controlled spot welding solutions provide unmatched precision and durability.

 

The Substantial Benefits of Robotic Welding

Implementing robotic welding technology represents a strategic investment that delivers measurable returns across multiple operational metrics:

Dramatically Increased Efficiency

Robotic welding systems operate at substantially higher speeds than manual processes while maintaining consistent quality. This capability translates directly to:

• Accelerated production cycles with higher daily output

• Continuous operation without fatigue-induced slowdowns

• Optimized torch movements that minimize non-productive time

• Simultaneous welding capabilities in multi-robot configurations

 

Enhanced Workplace Safety

Welding processes inherently involve numerous hazards, including extreme heat, bright light, harmful fumes, and ergonomic challenges. Robotic welding significantly mitigates these risks through

• Reduced operator exposure to welding arcs and spatter

• Comprehensive safety systems including light curtains, area scanners, and safety PLCs

• Elimination of repetitive motion injuries associated with manual welding

• Improved air quality due to optimized fume extraction integration

 

Unmatched Precision and Consistency

For high-volume production and applications requiring exceptional quality, robotic welding delivers:

• Perfectly repeatable welds across entire production runs

• Consistent penetration, bead appearance, and mechanical properties

• Adaptive capabilities that compensate for part variations

• Real-time monitoring and quality documentation

 

Reduced Waste and Environmental Impact

Precision robotic control translates to significant material and energy conservation:

• Minimized overwelding saves filler material and reduces energy consumption

• Fewer rejected parts and rework requirements

• Lower heat input reduces distortion and associated correction operations

• Optimized gas shielding reduces consumable usage

 

Yaskawa's Advanced Robotic Welding Solutions 

Through decades of technological advancement and application experience, Yaskawa MOTOMAN has developed unparalleled expertise in industrial robotics. Our welding-specific knowledge has established us as a worldwide leader in automated welding solutions that deliver:

• Comprehensive Application Understanding:

  • Deep expertise across diverse industries and welding applications

  • Application-specific robot models optimized for different welding processes

  • Advanced process knowledge in materials, consumables, and parameters

• Flexible Implementation Options:

  • Standard cells for rapid deployment

  • Custom-engineered solutions for unique applications

  • Scalable systems that grow with your production needs

  • Integration with existing manufacturing systems

• Exceptional Customer Support:

  • Comprehensive training programs for operators and maintenance personnel

  • Responsive technical support from welding process experts

  • Preventive maintenance programs that maximize uptime

  • Robust parts availability and service network

Our commitment extends beyond the initial sale to the complete lifecycle of your robotic welding system. We provide the training, support, and expertise needed to help you fully realise the potential of your automation investment.

 

Making the Transition to Robotic Welding 

The transition to robotic welding represents a significant advancement in manufacturing capability. To ensure a successful implementation:

1. Assessment: Begin with a thorough evaluation of your current welding processes, identifying applications best suited for initial automation

2. Planning: Develop a comprehensive implementation strategy addressing technology, workforce training, and production integration

3. Partnership: Select a robotics provider with proven industry experience and comprehensive support capabilities

4. Implementation: Execute a structured deployment with appropriate training and process validation

5. Optimisation: Continuously refine your robotic welding operation to maximize return on investment

If you're ready to explore how robotic welding can transform your manufacturing operation, our team is prepared to help you navigate each step of the journey. From initial assessment through implementation and ongoing optimisation, Yaskawa provides the expertise needed to ensure your success.

Ready to revolutionise your welding processes? Our expert consultants can help you discover how robotic welding solutions can add substantial value to your business.