Pros and Cons of Robotic Welding

Robotic welding is a type of welding where industrial robots perform welding tasks. As technology advances, robotic welding is becoming more prevalent in industries that require precise and efficient welding. In this article, we will define robotic welding, discuss the different types and processes, highlight the pros and cons of this innovative welding method, and analyze its impact on industries.

Content: 

I. Types of Robotic Welding

II. Processes of Robotic Welding

III. Pros and Cons of Robotic Welding

IV. Impact of Robotic Welding on Industries

I. Types of Robotic Welding

Welding robots are programmed to follow specific instructions and can perform the same welding tasks repeatedly with a high degree of accuracy. There are five types of robotic welding, that is, arc welding, resistance welding, laser welding, plasma arc welding, and electron beam welding. 

1) Arc Welding

Arc welding is a type of robotic welding that uses an electric arc to generate heat and melt the metal. The two most common types of arc welding used in robotic welding are Gas Tungsten Arc Welding (GTAW) and Gas Metal Arc Welding (GMAW). GTAW uses a non-consumable tungsten electrode to produce the weld, while GMAW uses a consumable wire electrode.

GTAW is commonly used when a high level of precision and accuracy is required. It is commonly used in industries such as aerospace, medical equipment, and electronics. GMAW, on the other hand, is used in industries such as automotive and heavy equipment manufacturing.

2) Resistance Welding

Resistance welding is a type of robotic welding that uses pressure and heat to join the metal. The two most common types of resistance welding used in robotic welding are spot welding and seam welding.

Spot welding is commonly used in the automotive industry to join sheet metal parts. It is a fast and efficient process that requires minimal material preparation. Seam welding is used when a continuous weld is required, such as in the production of fuel tanks, radiators, and other similar components.

3) Laser Welding

Laser welding is a type of robotic welding that uses a laser beam to produce the weld. The laser beam is focused on the metal, creating a high-intensity heat source that melts the metal and fuses it together. Laser welding is commonly used in the automotive and aerospace industries, where a high level of precision and accuracy is required.

4) Plasma Arc Welding

Plasma Arc Welding (PAW) is a type of robotic welding that uses a plasma torch to produce the weld. PAW is similar to GTAW, but it uses a plasma arc instead of a tungsten electrode. PAW is commonly used in industries such as aerospace and medical equipment manufacturing, where a high level of precision and accuracy is required.

5) Electron Beam Welding

Electron Beam Welding (EBW) is a type of robotic welding that uses a beam of high-energy electrons to produce the weld. EBW is commonly used in the aerospace industry, where it is used to join large structural components together.

II. Processes of Robotic Welding

Just like other welding modes, robotic welding shall also follow some steps and processes to produce the perfect weld. 

Step 1: Programming

This involves creating a set of instructions for the robot to follow, which includes the welding path, welding parameters, and the sequence of operations. The programming can be done offline or online, depending on the type of robot and the welding task.

Step 2: Workpiece Preparation

The workpiece preparation involves preparing the metal parts to be welded. This includes cleaning, deburring, and aligning the parts to ensure a proper fit. The workpiece preparation is critical to the success of the welding process, as any misalignment or contamination can affect the quality of the weld.

Step 3: Joint Tracking

Joint tracking is the process of tracking the joint to be welded. This is done by using sensors or cameras to locate the joint and adjust the welding path accordingly. Joint tracking is essential for ensuring that the weld is placed in the right location and at the right angle.

Step 4: Welding Techniques

As mentioned above, there are five different welding techniques used in robotic welding. Arc welding, resistance welding, laser welding, plasma arc welding, and electron beam welding are suitable for different industries and welding materials, thus welders should set the right welding technique based on the industry, the type, and the thickness of the welds.

Step 5: Quality Control

Quality control is an essential part of the robotic welding process. This involves inspecting the welds to ensure they meet the required specifications. The inspection can be done manually or using automated systems such as cameras or sensors. Any defects or inconsistencies are corrected before the final product is shipped.

III. Pros and Cons of Robotic Welding

Compared with traditional welding methods, robotic welding has several advantages. 

1) Higher efficiency: robots can work continuously without taking breaks or getting tired, leading to faster and more efficient welding. This can result in increased productivity and cost savings for businesses.

2) Higher consistency: robots can perform the same welding task repeatedly with the same level of accuracy, leading to consistent results. This can lead to higher quality products and fewer defects.

3) Safer: robots can be programmed to work in hazardous environments or areas that are difficult for human welders to access. This leads to increased safety for workers and a reduction in workplace accidents.

4) Higher quality: robotic welding produces high-quality welds with minimal defects. This can lead to better product quality and a reduction in the number of rejected products.

However, there are also some disadvantages to robotic welding. 

1) Higher initial cost: the initial investment in robotic welding equipment can be high, and the maintenance costs can also be significant. This can be a barrier to entry for small businesses.

2) More complex and time-consuming programming: this requires skilled programmers who may not be readily available in some industries.

3) Less flexible: robots are not as flexible as human welders and may struggle to adapt to changes in the welding environment. This can limit their ability to perform certain welding tasks and may require additional programming or customization of the equipment.

IV. Impact of Robotic Welding on Industries

Robotic welding has had a significant impact on industries that require precise and efficient welding. The automotive industry, for example, has adopted robotic welding extensively, resulting in increased productivity and cost savings. Robotic welding has also been adopted in industries such as aerospace, medical equipment, and electronics.

One of the biggest advantages of robotic welding is the ability to perform tasks in hazardous environments or areas that are difficult for human welders to access. This has led to increased safety for workers and a reduction in workplace accidents.

In conclusion, robotic welding is getting more popularity in industrial manufacturing and may replace multiple manual welding. If you want to buy robotic welding equipment or machines to maximize robotic welding efficiency, you can consult Megmeet's professional sales manager by clicking: https://www.megmeet-welding.com/en/lxfs/index.aspx. If you want to learn more welding tips, you can collect Megmeet News Center Page or follow our Linkedin page.