In the manufacturing industry, companies constantly strive for improved quality and productivity while still keeping costs low. In order to make these improvements, manufacturing companies often turn to technology, and this is especially true in the case of welding.
Welding, at its most basic form, is the process of joining two materials through the application of heat and pressure. When people think of welding, the word often conjures an image of a protective mask and a pair of heavy gloves handling a torch. While manual welding still has its place in the industry, a growing shortage of professional welders has left a substantial gap. As result an increasing number of companies are investing in robotic welding setups.
Installing a robotic welding apparatus takes a great deal of consideration, planning and significant investments in time and money. However, companies that have implemented robotic welding in their procedures have discovered innumerable long-term benefits.
We can supply any robotized welding cell at very affordable prices, all produced with quality components!
Robotic welding makes up 29% of all robotic applications in industry, topped only by robotic material handling. Automatic welding is most commonly used in the manufacturing and engineering industries to increase the efficiency of companies and labs.
Most commonly, they are used for resistance spot welding and arc welding for high quantities of product. Two processes our welding machines handle very well:
RESISTANCE SPOT WELDING
Robotic resistance welding is an economical way to weld two pieces of sheet metal together at a single point, or spot. This type of welding is commonly seen in the automobile manufacturing industry, where it is used to weld sheet metal into the form of a car. Many of the spot welders in the automobile industry are robotic and can be seen working on car assembly lines.
The spot welding process works by applying two copper alloy electrodes to the parts being fused and passing a current through the materials. The current heats the metal and causes it to melt, forming a pool between the pieces at the spot applied. Upon cooling, the pieces fuse together.
Robot welders are ideal for this application as they are able to place multiple spot welds with extreme accuracy and efficiency.
Robotic arc welding has grown as an industry only recently, but is quickly catching up to spot welding as the most popular robotic welding method. The process uses a power supply to generate an electric arc between a torch-mounted electrode and metal. This arc produces a temperature of about 6,500 degrees Fahrenheit at the tip of the torch. This heats up the metal, producing a pool of molten metal beneath the torch that solidifies upon cooling. Upon cooling, the parts permanently fuse together.
Because of the extremely high temperatures produced, the metals involved in this process will often react chemically with the oxygen and nitrogen in the surrounding air. This can compromise the integrity of the weld joint. For this reason, many arc-welding processes involve a process called arc shielding. This process covers the arc and the molten metal with a protective shield of gas or vapor, minimizing the contact between the molten metal and the surrounding air.
The extreme heat and chemical reactions involved in arc welding make it a perfect application for robotics, as this reduces the exposure of workers and operators to these risks.