How Welder Cobots Enable More Welding Applications

A welding robot refers to an automated machine specifically designed for welding tasks. Robotics and welding have a longstanding connection, which is why robotic welding applications frequently yield significant returns on investment. Numerous integrators and manufacturers specialize in this field, offering expertise in robotic welding solutions.

The objective of this article is to delve into the fundamentals of robotic welding and highlight its benefits. By understanding these basics, you can begin exploring the possibilities of automating certain processes within your operations.

The Benefits of Cobots in Welding

Rapid and Simple Learning Process

Collaborative robots provide the capability for individuals familiar with welding to manually guide the robot by hand, moving the arm and torch along a predefined path to carry out the welding process. This user-friendly functionality allows manufacturers to quickly train someone who may have little to no experience with robotics, enabling them to operate the robot within a matter of minutes instead of spending hours or even days on extensive training.

Safe to Be Around

While collaborative robots offer the advantage of enabling humans to work safely alongside or in close proximity to robots, manufacturers must prioritize taking appropriate precautions. It is important to recognize that welding, regardless of whether it involves a robot or human manipulation, already carries inherent risks such as arc flash, weld spatter, hot parts, sharp wire, and exposure to high currents of electricity. It should be noted that the safety of collaborative welding depends on the implementation of comprehensive precautions within the welding environment. Therefore, the use of personal protective equipment (PPE) and training remains essential, as determined through a thorough risk assessment of the robot, end-of-arm tooling, the workpiece, and the robot work area.

Convenient to Relocate

In contrast to larger and heavier industrial welding robots, which typically weigh approximately 150 kg, collaborative robots like the HC10 are significantly lighter, weighing only 52 kg. This lightweight design allows them to be placed on a wheeled base or a small fork truck, offering mobility and flexibility. As production requirements evolve, cobots can be easily relocated within the factory. An ideal scenario for such a robot would be a factory or job shop that already has welding tables configured for human use, where the cobot can be effortlessly wheeled in to complement manual labor.

Suited to High-Mix, Low-Volume Production

These highly trainable robots are a perfect fit for manufacturing scenarios characterized by a diverse range of products and limited production quantities. Unlike the time-consuming process of programming a robot for a specific part that requires only 50 units, operating an intuitive cobot can be accomplished within minutes. This rapid setup enables quick transitions between different tasks. Additionally, employing robotic welding in fast-paced, low-volume production not only minimizes cycle time and ensures consistent quality, but also offers the potential to allocate human workers to more valuable assignments. Skilled welders can then focus on complex welds that demand their expertise, surpassing the capabilities of robots.

Minimizes Cost per Part

By reallocating manual workers to alternative operational responsibilities like custom welding, an opportunity arises to reduce the cost per part. When a collaborative robot operates alongside a skilled welder who is engaged in a different task, there is significant potential for gradually decreasing the average cost per part, particularly after achieving a return on investment (ROI). This parallel operation of a robot and a skilled worker opens avenues for long-term cost reduction.

Welds Longer Continuous Seams

In today's marketplace, maintaining high quality is paramount, particularly for high-mix, low-volume production runs. Collaborative welding robots play a crucial role in achieving this by enabling the creation of longer and continuous weld seams. Unlike skilled welders who can typically weld a two-foot seam in one continuous motion, cobots have the capability to create up to a four-foot seam. This becomes especially advantageous for longer parts, as it reduces the need for frequent starts and stops, resulting in higher-quality welds. Moreover, such parts often require larger welding cells that occupy significant dedicated floor space. In contrast, a collaborative robot can be easily manoeuvred and positioned directly at the part's current location, eliminating the need for extensive reconfiguration.

Conclusion

We are a trusted partner and leader in the manufacturing of robotic solutions. One of the remarkable benefits of collaborative robots lies in their versatility, extending beyond just welding tasks. In a welding environment, cobots can be effectively employed for various other applications. These include tasks like loading/unloading spot ped welders, loading/unloading standard welding workcells, conducting part and weld seam inspections, placing post-weld parts into containers, as well as picking and placing parts. If you're keen on exploring ways to enhance the capacity of your robotic welding processes, we invite you to chat with us for further information and insights.