We are all aware that since machines have entered our daily lives, our lives have become much more accessible. With the help of robotic tasks, we can produce much faster and more efficiently, which increases profits and saves us time and direct labor costs. This also applies to the construction industry, particularly welding various metals and structures.
Automation in manufacturing has encompassed four industry groups with the highest percentage of automation:
- electrical equipment
- components and appliances
- computer and electronic products
- mechanical engineering and transport equipment
To beat the competition, companies in the metalworking industry must find ways to increase their productivity, minimize defects, and achieve direct economic labor and raw material costs. One good solution for both large and small fabrication shops is the implementation of automated welding machines.
However, introducing a robotic welding cell into a plant requires careful planning. This is important because the system must operate efficiently and productively for the manufacturing process to be profitable.
One of the areas where robots are used the most is assembling different types of parts, pieces or components. Robotic welding systems have wide applications in various manufacturing aspects. They can perform repeatable, high-volume welding processes.
Automated welding systems provide high-speed operation and accuracy down to the millimeter, which ensures a correspondingly better production chain. No wonder, therefore, that investment in automated machines in manufacturing has an excellent return.
85% of production tasks can be automated. Most of these tasks involve metal handling, machine servicing and assembly. They are characterized by repeatability and can also be performed by simple robotic machines.
In 2025, the predictability per employee will reach 10-30% compared to now. Also, the forecast shows that due to the greater use of robots, labor costs in manufacturing in 2025 will be, on average 16% lower in the top 25 economies than they are now.
Unfortunately, not all industries and economies will reap the benefits of auto-privatized production. This is due to differences in the pace of automation with advanced robots. The main factor remains the economic difference between the cost of human labor, the investment and operation of robotic systems, and the technical capacity of machines to replace human labor.
What is the application of robotic welding in the industry?
Whether you're working in furniture or any other sector, robot systems can weld complex electronic modules and simple components with better precision than humans - achieving a tolerance of up to 0.1 mm. The robot welder's head can be fitted with any device that can be controlled by a master processor and used by a human.
When large-sized devices are used in manufacturing, using robots instead of humans is a significant advantage. When at full speed, a standard robot can lift up to 120 kg. and provide ten cycles of welding per minute. This fact guarantees that any type of production will be more productive with the help of a robot.
Some types of welding pose more significant challenges for robots than others, but eventually, they are introduced into production lines in small batches.
Companies gradually introduce robotic welding systems into their operations, starting with just one welding cell and adding more until they entirely automate the process.
Advantages of robotic welding
Robotic welding application brings many advantages to the business and is becoming an increasingly preferred option amongst fabricators in the industry.
Greater speed
A primary benefit of using a robotic welding system is the speed with which it can complete tasks. Compared to humans, machines operate much more quickly than humans, resulting in superior throughput. Increased production efficiency and quality are also possible through such technology.
Traditional welding techniques can be time-consuming and sometimes cumbersome, making robotic systems an appealing choice for manufacturers who need fast turnaround times. Cells with automated welding technology can often move between individual welds, speeding up the overall process.
Due to the consistent and efficient working, manufacturers can economize by dispensing with on-site welding staff.
Higher productivity and accuracy
Almost all of you will agree that quality and productivity are essential to any industry. We can achieve incredible speed, precision, and overall production efficiency with welding robots. Machines allow us to achieve consistent cycle times because they have a constant process.
In automatic welding, the production is better and the process is not interrupted. This welding type is highly preferred when a part has a hard-to-reach section because of the unique design for reaching the smaller areas. Welding robot manufacturers have come up with unique designs to reach smaller areas.
Robotic welding cells provide high productivity because they do not need rest or rest days. Automated welding systems work consistently and thoroughly. They can move from one weld to another, making the entire process faster. With the help of robotic welding automation, manufacturers can save on paying employees and provide safe conditions and input costs.
Fewer mistakes at work
Welding machines make fewer mistakes than humans, no matter their age and everything, including the power supply, is under control. With robotics, wire feed is regulated and seam accuracy is improved. The finished work is solid and precisely crafted.
Less cost
Robotic welding can also save money because hand soldering is more expensive and time-consuming. Humans need a particular skill and attention to do their job correctly. For such tasks in the industry, highly qualified and well-trained personnel are required and their cost is very high. The introduction of robotic systems can reduce production costs.
There are other key factors in profitability, using robotic welding systems - they save a lot of energy and less material is wasted, compared to manual work. Also, profitability is a plus. On average, 12 to 15 months is an achievable time frame for a return on investment for robotic welding systems.
In this case, this applies to most big and small businesses and those with frequent changes in production. Additionally, the machines have no breaks or holidays, making production a continuous process and, therefore, more profitable for the manufacturer.
The material savings in automatic welding is due to the ability of this type of machine to maintain an optimal weld geometry, which is a common problem in semi-automatic welding and costs money.
The rationale for investing in robotic welding systems is based on proven profitability. The return on investment can be demonstrated by achieving higher productivity and high-quality welds.
Achieving this can save manufacturers from often costly and time-consuming rework. It is worth mentioning that after welding is complete, the welds are cleaned and painted (powder and wet), for which investment in machinery is required.
Greater safety
Also, manual welding is dangerous to perform and requires safety measures to be in place. The sparks, heat, flashes and fumes make welding a risky task for a human, but pose no problem to the machine.
By robotic welding, the risk of accidents to employees is avoided, time and resources are saved in ensuring safety conditions and also the cost of the item produced is reduced.
Disadvantages
One disadvantage of robotic welding systems is the initial equipment investment, etc. Of course, such equipment is costly and can be a hurdle for some small businesses just starting. But no one can deny the long-term benefits of introducing systematic welding systems into production because they bring long-term benefits.
There are several key factors to consider for companies that have purchased a robotic welding system and are looking to upgrade the machine or learn more about its capabilities. Companies considering investing in automated welding systems would do well to consider how to calculate return on investment.
One way is to compare the current production rate with the potential production rate of the welding robot.
In this case, the transfer of existing jobs involving physical activity to other parts of the production chain can also be considered and may help. In fact, up to 75% of the cost of semi-automatic welding is labor.
For example, if this work is reinvested in other operations to increase productivity, the return on robotic welding systems will undoubtedly increase.
Types of welding machine
The machine types used for welding are KEMPPI and MILLER. They are designed for welding ferrous metals, stainless steel and aluminum. They can also be used to weld sheet metal products and tubular structures up to 6 meters in size and 3 tons in weight.
Welders manufactured by KEMPPI can create or independently control parameters and settings sources. In addition, KEMPPI engineers have developed techniques to solve the specific challenges of welding thin surfaces and many other tasks.
