LONG production lines working 24 hours a day utilising robotic welders is a method of manufacturing normally associated with the automotive industry. But in fact robotic welding is being adopted by an increasing number of manufacturers, with most facing skills shortages and increasing labour costs.
Lower cost equipment, higher levels of integration of robot and power source with improved equipment functionality are just some of the latest developments according to Paul Deuchar, MD of Argon Technology.
“Robots come with far more functions, they are easier for seam tracking and touch sensing with welders having new processors available due to invertor power source optimisation,” Deuchar told Manufacturers’ Monthly.
A sentiment echoed by John Cameron, manager of automation at Lincoln Electric who suggests robotic arc welding continues to impact upon manufacturing to automate production arc welding processes.
“Moving to robotic arc welding effectively builds the welding skill into the robotic system. The other main drivers continue to be reduced costs, improved quality and increased productivity,” he said.
Deuchar claims weld quality has improved due to more sophisticated power sources that integrate with the robot and allow precision arc control during the welding process.
“The more advanced power supplies have simplified the parameter set up and qualification process, this coupled with the increased integration capabilities means that power source output can directly match the robotic torch motion.”
Robotic Automation’s MD, Colin Wells believes robotics offer an unparalleled level of repeatability and consistent quality, pointing out that today’s quality standards require high levels of accountability and traceability.
“This is now ensured via arc weld quality monitoring systems, especially important to automotive manufacturers,” Wells told Manufacturers’ Monthly.
Cameron believes any industry that is joining metal with an arc welding process will benefit from robotic welding, especially if they are a part of ongoing welding operations.
“The other possibility is a smaller quantity of repeat items with each containing a significant amount of welding. In the end it’s all about having enough work to keep the robot welding all day, every day. Industries that are having difficulty in sourcing and keeping production welders may also benefit from robotic arc welding.”
Deuchar agrees that robotic welding systems are becoming cheaper and more powerful.
“Converting to robotic welding really depends on the job and application,” he said. “Robotic welding combinations can start from $150,000 for a lower end robotic MIG welding system and ramp up from there depending upon welding technology required. However nothing extra is required beyond normal welding consumables except standard maintenance,” Deuchar said.
Wells says that costs for installation depend on the complexity of the system required with the average cost between $50,000 and $100,000.
“If a company employs a welder at $40-50k per year, working one shift as day, then a $100k robotic welding installation will pay for itself in two years. A robot is not bound by normal shift hours, works faster, is more consistent in the quality of its work so the ROI is more immediate,” Wells said.
With the US and Japan leading the charge with robotic welding, Deuchar believes robotics in Australian manufacturing still has a big development curve ahead of it.