Robotic Welding: 12 Pros and 5 Cons You Need to Know

The automotive industry pioneered the use of robotic welders for decades. With the high demand for consistent and precise welds on automobile frames using a variety of different methods of welding as well as materials, robotic welding quickly became the industry standard.

However, as the benefits of robotic welding became more widely recognized, its use has expanded beyond the automotive industry to aerospace, construction, and manufacturing.

Robotic welding machines can now perform complex welding operations, such as welding parts with varying thicknesses or welding in tight spaces that may be difficult for human welders to access. Additionally, using artificial intelligence and computer programming allows for precise adjustments to welding parameters, ensuring consistent quality and reducing the risk of defects.

Beginning with simple two- and three-axis welding robots, they are now capable of entirely new levels of maneuverability, reliability, and meeting specific job requirements. With the integration of artificial intelligence, computer programming, and robotic interfaces, implementing robotic welding and manufacturing is no longer exclusive to multi-billion dollar companies like General Motors.

You can enlist the services of Glenn Metalcraft, a company experienced in handling such welding jobs.

Welding Process

Welding is a concept that has been around since the Bronze Age—two pieces of metal joint by superheating a connection point known as a joint. 

In general, the heat generated by welding can cause the metal to reach a molten state, allowing fusion to occur at the atomic level. Robotic welding utilizes arc welding, which generates heat by creating an arc between the welding electrode and the workpiece via an electric current. The heat melts the materials, forming a bond.

A line of weld known as a bead is drawn along the joint seam to fuse the metals. Gases such as oxygen, carbon dioxide, and argon can be used to control the reactivity of the weld. 

Welding is a process that permanently joins two pieces of metal, creating a strong bond between them. Once welded, the joint cannot be separated without causing damage, which typically involves mechanical cutting or using a cutting torch. 

It is essential to carefully consider the design of the weld and ensure that it meets the necessary strength and durability requirements to prevent the need for future separation. Also, proper welding techniques and equipment should be employed to provide a quality weld, meeting industry standards.

Robotic Welding as a Tool of the Future

Robotic welding offers significant advantages over manual arc welding. While skilled welders can achieve precision, robotic welding provides for more consistent precision and accuracy throughout the day.

Robotic welding cells can operate around the clock, increasing efficiency and productivity. Advanced software and controls also allow for customizing the welding process to meet specific requirements, resulting in improved quality and reduced errors.

Robotic welding utilizes a sophisticated robotic armature with multiple points of articulation, which are computer-directed, to weld metal sheets together. The robotic arm is equipped with optics that allow it to “see” the welded material, providing imagery that the program can use to identify pre-coded regions of the welded workpiece.

The robotic arm can move itself and the work platform to align the pieces properly, resulting in efficient and accurate welding.

In robotic welding, a movable platform may hold the item being welded and can change angles, swivel, and move in combination with the robot arm to fit any desired angle. At the end of the robotic arm is the arc welder, which follows the programmed pathway to tack and weld the fitted pieces together. 

Once the program is activated, the robot arm goes to work, welding the materials and moving itself and the work platform to align the piece properly. After welding, the welded piece is allowed to cool, and the next programmed item is clamped to the work platform for the next welding task.

Pros of robotic welding

Robotic welding offers certain advantages over manual welding processes.

Quality of workmanship

• Robotic welding provides precise and uniform welds that meet strict industry standards.
• Prescribed amounts of welding wire and gas are used precisely, resulting in less waste and reduced material costs.
• Expertise is handled by a computer program, improving efficiency and consistency.
• Robotic welding cells can operate around the clock, improving turnaround time.
• The use of advanced software and controls allows for the optimization of the welding process, resulting in improved efficiency, quality, and consistency.

High-production

• Robotic welding offers significant advantages in high-production manufacturing environments, allowing a single robot to perform repetitive tasks precisely and consistently over long hours.
• Traditional manufacturing methods that rely on skilled human welders may require multiple shifts or risk falling behind when meeting production demands.
• Robotic welders work faster with zero degrees of variance when it comes to the consistency of their work, ensuring the uniformity of products.
• The ease of operating a robotic welder after training allows for a more flexible workforce minimizing downtime due to limited resources.

Health and Safety

• Robotic welding reduces the risk of injury to workers by eliminating the need for direct human involvement in the welding process.
• By reducing exposure to harmful fumes and radiation, robotic welding can significantly improve the health and safety of workers.
• The use of robotic welding technology can help companies comply with safety regulations and avoid potential fines and legal issues related to workplace safety.

Cons of robotic welding

Here are some disadvantages of robotic welding you should know:

• Initial setup: Setup for a job may involve creating a new program or modifying an existing one, selecting the appropriate welding wire and gas, and configuring the welding system’s parameters to ensure optimal performance. This initial setup for a job may require a significant investment of time and resources.
• Limited flexibility: While robotic welders are great for repetitive tasks and large-scale production runs, they may not be as well-suited to smaller, more specialized welding jobs that require a high degree of flexibility and customization.
• Lack of adaptability: While robotic welding is excellent at welding consistent products over long periods, it may not be as adaptable as human welders in situations where designs, materials, or welding processes need to be changed quickly.
• Not portable: Robotic welding devices weigh several hundred pounds and must be installed in a controlled environment to function properly.  
• Not weather resistant: Some portability limitations apply to weather and environmental conditions. Trained welders can weld in the rain, snow, underwater, and in blowing sand if necessary. Robotic welders are limited to factory or laboratory environments where the elements won’t damage them.

Contact us

Get in touch with us if you want to take advantage of the latest robotic welding technology to create products that meet your specifications. We provide increased efficiency and flexibility for manufacturers and engineers with a variety of robotic welding services.

Reach out for technical know-how experience that will catapult your welding needs into the next century. Our specialists know metal fabrication, welding, and other metalcraft needs.