These days, welding handling robotic are getting popular and in huge demand in diverse industries across globe. It is mostly used for automotive component production in high volumes. Its usage has only helped to enhance overall consistency and quality. GMAW (gas metal arc welding) when implemented in fabrication process is found to be a significant contributor. Coated, thin materials do offer some challenges. But welding steel is regarded to be routine. Current advancements noticed in power resources is seen to change the topic of arc welding robot application to “What appearance is desired in the weld?” rather than “Is it possible to weld my part?
About GMAW process
Wire electrode is used in the Industrial welding handling robotic arm process to include material, so as to create weld deposit. It allows quick travel speed as well as ensures robotic process tolerance, which can be maintained at minus or plus half of wire diameter. Generally, weld cosmetics are accepted in the form of uniform, smooth bead shape, but without any properly defined solidification lines.
To conduct filler and current material, GTAW process also uses non-consumable electrode. It is typically regarded to be precision process. Electrode gets fed externally within the puddle. The welders balance skillfully base material melting process while adding filler material. This in turn develops specific defined solidification lines along with ‘ripple’ created in bead. The GTAW weld’s cosmetics of ‘layered penny’ or ‘stacked dime’ are found to be aesthetically pleasing for many. Others even refer it to represent a handcrafted quality.
This process has the ability to combine consistency and productivity with GTAW weld cosmetic appearance. For several years now, aluminum weld stands benefitted. The current trend is also witnessing usage of aluminum to diminish truck trailer weight, thus creating an interest for robotic arc welding. More details can be derived at https://www.evsrobot.com!!
Both small and large companies can benefit from welding automation, ranging from weld consistency to improved productivity to reduced labor, material and production costs. Usage of robots is no longer restricted to just large manufacturers. Even medium and smaller ones and implement this advanced technology. Few benefits are given below:
1# Productivity increase: Welded components can be processed with robotic ability about 3-5 times much faster than manual human operation. It can move quickly between the joint positions and withstand greater on-time arc, thus increasing output substantially.
2# Repeatability & consistency: More focus and advance skill levels is necessary for manual welding to achieve repeatability & better consistency. Similar weld cycle can be performed continuously by the robotic welder 24/7.
3# Greater flexibility: Multi-jigs swapped out during each production run is essential for manual welding procedure. With robots, it is possible to save precious time as well as do away with tool changes like grippes to grab any portion, irrespective of position, shape or size on assembly to hold tight during welding procedure.
4# Safety: Welders do face several safety risks like exposure to toxic fumes, gases, electric shocks, flash burns resulting in damage to eye cornea, etc. With robotic welders, accidents can be significantly reduced.
5# Quality: Superior quality results can be derived with a robotic welder to ensure appropriate welding angle, distance and speed with repeat in accuracy of about (+0.04mm). This ensures consistent production of every individual welding joint to very high standards and reduces significantly expensive rework.
6# Reduce consumables: Weld size in manual welding gets determined by the operator. This might general larger welds, much more than what is actually required. On the other hand, robots have been programmed to weld always to correct joint size and length of required joint, thereby saving money with time.
7# Labor: Since skilled workers are in acute shortage, robotic welders have been stated to be a boon. But still, there will be necessary manual welders to do jobs that require great amount of customization. The robotic welder on the other hand will help to alleviate issues especially during busy hours, thereby saving on the extra hours which otherwise needs to be put in to train the additional staffs.
8# Weld distortion reduction: Weld distortion takes place due to contraction and expansion of adjacent base metal and weld metal during welding procedure’s cooling & heating cycle. Proper tuning of robotic welders is done to correct weld size for joint requirements, to reduce weld pass amount and to complete the procedure with great speed. This in turn reduces heating of adjacent metal which might expand, causing distortion.
9# Reduced production expenditure: With improvements noticed in productivity, consistency and quality, the robotic welding system has been designed to create affordable parts. Besides saving, it also consumes very less energy as well as requires less consumable expenditure. At the same time, insurance costs and worker compensation is also reduced.
It is for the above reasons that robotic welding is gaining popularity the world over.