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What happens in robotic welding?
Of course, welding robots have also entered the Industry 4.0 era. Operational data processing and analysis is improving at a rapid pace.

What happens in robotic welding?

From the first welding robot in the 1960s to the advanced installations that exist today, the welding robot has come a long way. The fact that it is more popular than ever has everything to do with the opportunities it has gained on the one hand and the difficult job market on the other. Manufacturers who want to grow without compromising on quality do have to resort to technology because good welders are increasingly difficult to find. The implementation of welding robots then helps ensure quality, save material and increase safety. What can we expect in the coming years?

Efficiency is paramount on the production floor. Therefore, welding robots are less and less often on their own. With the addition of an extra robot to take care of material handling, operators no longer need to enter the cell and the welding robot can continue to do its thing continuously. As a result, cycle times can be a little shorter, costs a little lower and safety higher, because operators are no longer at risk of inhaling harmful welding fumes. 

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Implementing welding robots helps ensure quality, save material and increase safety.

Addition sensors

The welding cell itself is also expanding. The addition of sensing technology (think sensors) allows welding robots to adjust themselves and their welding parameters to individual workpieces. The idea is to thus increase weld quality and speed of welding operations, even when there is more variation in the workpieces. So forget the misconception that welding robots can only handle large series work. If a workpiece falls outside predefined tolerances, an operator is called in. In addition, sensing technology helps monitor the weld, for example to ensure quality or further optimize the process. 

Real-time data analysis

Of course, welding robots have also entered the Industry 4.0 era. Operational data processing and analysis is improving at a rapid pace. Since every weld needs proper inspection to pass the quality control process, these tools enable validation of joint strength, weld penetration and sealing of each seam during welding. Thus, arc tracking systems can automatically detect errors and correct the weld operation. Other capabilities include edge detection and tracking of weld penetration, checking weld penetration to specifications, measuring joint width and profile, and contour management with image acquisition for complex welds.

Integration with upstream and downstream processes

Welding robots are often set up in a production line, where an inspection step happens both before and after. Tomorrow's welding robot will no longer act as an island. By integrating it directly with other data streams and software, the entire production line can run at a higher speed. A great example is the feeding of pieces. By integrating that into the operation of the welding cell, the welding robot never has to stand still, as both the feeding and the quality control before and after are assured. A second nice benefit is that it also reduces the chance of defective welds. That, in turn, helps save on time and materials.

Cobots for greater convenience

In the past, manufacturers had to employ programmers to set up indus-trial robots and manage any change to production parameters or new software code. In addition to needing skilled programmers to work on the robots, each change in operational parameters also increased downtime and lowered productivity. The introduction of cobots to the shop floor removes some of that complexity and barrier. No more programmers are needed. Welders can easily set parameters and control the weld through teach-in programming techniques. They can also work side-by-side with humans.   

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