How Is Robotic Welding Technology Revolutionizing Efficiency and Safety in Modern Industries?
Modern technologies have significantly transformed several industries in the last few years. In the welding industry, welding robots represent the form of advanced technologies that have revolutionized various welding processes. Robotic welding has emerged as an automatic welding methodology that enables several businesses to automate their processes, improve accuracy, increase safety, and lower lead time. This modern welding process is the most productive when it is incorporated for high-volume and repetitive tasks.
Welding robots perform and manage various welding tasks and possess the capability of being reprogrammed as per the intended project. However, these cutting-edge robots do not eliminate the role of humans as welders still have the control and supervise the welding robots. Moreover, these robots benefit numerous manufacturing processes with reduced wastage, improved safety, and précised results.
How does robotic welding work?
Welding robots incorporate an arm that has the potential to move in three-dimensional and welding metals together. Then, there exists a wire feeder that sends a filler wire to the robot and the arm has a high-heat torch at its end that melts metals during the welding process. Moreover, some certified human operators are employed to maintain these robots and provide them with instructions. In addition, there is a control box which is handled by operators to control the robot’s programs, and an operation box that helps to start the operation. Further, the robotic arm’s tool warms up to melt metal and connects the components. Then a wire feeder supplies extra metal wire to the arm and torch as per the requirement. For welding other portions, the arm moves the torch to the cleaner to clear any metal splatters to avoid freezing in the same place. In addition, there are arc shields that prevent the high-heat arc from mixing with oxygen to safeguard the workers and the nearby areas.
Why has robotic welding become popular?
In the last couple of years, robotic welding has become popular among contract manufacturers and job shops due to several advantages. One of the notable benefits of using robotic welders is that they are cost-effective compared to human welders. Hiring, providing training, and retaining skilled human welders is an expensive process. Robotic welding technology helps businesses streamline their workforce by utilizing robotic welding technology. It allows one highly skilled welder to oversee multiple automated cells. This approach reduces labor costs and enhances operational efficiency.
Moreover, robotic welders operate with remarkable speed and efficiency, consistently outperforming their human counterparts in terms of precision. They achieve up to 85% operational efficiency, while skilled human welders are able to reach around 20% only. Unlike humans, robots do not require breaks, undergo health issues, or experience other problems. This allows them to maintain a consistent quality of welds day after day. In contrast, human welders often have less than 50% arc-on time, a figure that declines further due to fatigue. On the other hand, robots achieve an impressive arc-on time of up to 95%.
Moreover, robots do not get distracted, which allows them to keep a steady weld speed, current, and other important factors. This consistency helps them produce high-quality welds every time. Therefore, using robotic welders for projects that require strict quality standards is a preferable choice.
In addition, welding robots significantly reduce the mistakes often associated with human welders. They consistently maintain high-quality welds regardless of the circumstances. This reliability helps minimize waste, making it easier to stick to budgets, especially on high-value projects. In addition, robotic welders are highly efficient in their use of consumables, such as filler materials. This efficiency decreases waste and extends the lifespan of nozzles and other consumables. As a result, businesses purchase these materials less frequently, leading to remarkable cost savings.
A look into popular robotic welding processes benefitting leading industries
Welding process is an art and science that demands extensive training and skill. Many professionals struggle to meet these qualifications. As a result, robotic automation has become increasingly common in today’s industry. A diverse array of machinery is now available, and robots adapt to various welding processes. The arc method is one of the most widely used techniques in robotic welding. This process generates high temperature, reaching up to 6,500 degrees Fahrenheit, through an electric arc that melts the metal. As the molten metal fuses the parts together, it solidifies upon cooling, creating a strong bond. Arc welding is an excellent choice for projects that require a large number of precisely connected metal components.
Moreover, resistance welding is a popular form of robotic welding due to its cost-effectiveness and versatility. In this method, an electric current flows between two metal pieces, generating heat that creates a molten pool to bond the materials together. Spot welding is a specific type of resistance welding primarily used to join thin metal sheets. This technique is commonly used in the automotive industry for assembling sheet metal frames.
Furthermore, tungsten inert gas (TIG) welding is ideal for projects that demand high precision, such as welding bicycle frames and other intricate products. This method is a form of arc welding that uses a non-consumable tungsten electrode to create the weld. Owing to the complexity of the process, TIG welding is usually slower compared to other welding techniques.
In addition, metal inert gas (MIG) welding utilizes a high rate of melted filler metal to form the weld. This process involves feeding a wire toward a heated weld tip. As a subtype of gas metal arc welding, MIG welding is particularly well-suited for applications that prioritize simplicity and speed.
Moreover, laser welding has become popular which uses a laser generator that transmits laser light through a fiber optic cable to a robotic cutting head. This technique enables the precise welding of components. This technique is commonly utilized in high-volume applications that demand exceptional accuracy, particularly in the automotive industry.
The development of such innovative welding processes has fostered the growth of the robotic welding market significantly in the last few years. According to Allied Market Research, the industry is anticipated to rise at a CAGR of 8.7% from 2019 to 2026.
DAIHEN strengthened its global presence by joining hands with Rolan Robotics
In April 2024, DAIHEN CORPORATION, a leader in welding and robotics technology, announced its acquisition of Rolan Robotics BV, a provider of welding and handling robots. This acquisition has opened extended opportunities for Rolan Robotics to expand its reach across the European robotics market and strengthen its technological integration within the DAIHEN group. Through this agreement, the companies together aimed to promote the development of innovative solutions in the core areas of robotics and welding technology. In addition, this acquisition has also reinforced DAIHEN’s presence across the globe and helped it gain significant recognition in the robotics and welding industry.
AGT Robotics and Gauge Capital came together to transform industrial automation
In August 2024, Gauge Capital, a private equity firm, partnered with AGT Robotics, a provider of robotic welding solutions for the structural steel and heavy metal fabrication industry. Through this acquisition, Gauge Capital supported AGT in reaching its full potential & growth objectives and delivering world-class products to its clients worldwide. Moreover, through this partnership, AGT is expected to expand its welding automation and fabrication technology with invaluable offerings. In addition, AGT’s focus on driving innovations, maintaining quality, and building relationships is anticipated to boost industrial automation adoption and accelerate its business growth in the coming period.
The essence
The process of welding has significantly evolved over the years, transitioning from traditional methods that required extensive manpower, time, and costs to more efficient solutions. Robotic welding has emerged as a modern alternative, addressing these challenges more effectively. Many automobile manufacturers have adopted robotic welding in their production lines due to its speed, precision, and enhanced safety compared to conventional welding. This shift has made robotic welding increasingly popular in the industrial sector.