4 hi-tech welding automation features that take production to a new level
Above all, more advanced welding automation solutions bring more flexibility and precision to production. The more we can automate, the more accurately the technology will manage the process from start to finish. It frees workers from heavy, manual work and offers them a new career path in robotics and robot operation. This trend is already well underway in the manufacturing industry.
But what added value do the various solutions for welding automation bring to the overall and the production process itself? These are the questions we will now explore in more detail.
Introducing welding automation solutions
It always depends on the customer’s production and objectives which technologies will ultimately make up the final solution. Here we present the most common ones that our customers have used to make a significant difference to their production:
Machine vision. One important advantage of machine vision is that it simplifies the requirements for mechanical positioning accuracy of parts and improves the accuracy and quality of the final product. The typical starting point before machine vision is that a human operator loads the parts onto a welding jig and clamps them in place using mechanical presses, for example. The robot then welds the parts along a pre-trained path, ignoring any manufacturing changes in the parts. If a machine vision system is used at this stage, the requirements for the jig can be simplified. The machine vision images the parts as they are picked and corrects the simulated orientation from the image data to match the reality, after which the robot accurately loads the parts to be welded into position for welding. The machine vision detects even the smallest manufacturing and positional errors, which can then be taken into account during welding. The final assembly is created more accurately and faster than with more traditional methods.
Laser search and tracking. Laser search scans the location of the groove before welding begins. In a more traditional solution, the robot welds the groove according to predefined parameters, despite the fact that the groove may not be in exactly the same position every time, depending on manufacturing and other part characteristics and defects. If the rail is welded to such a part according to a pre-learned path, it will probably not always be on the right spot. With laser scanning, the position of the rail can first be scanned, allowing the robot to correct its program and determine the welding path more accurately. This way, the weld will be on target every time. During the welding process, the tracking of the gouge monitors the welding process throughout and adjusts the welding process according to what happens during the welding process. For example, changes in the air gap can be continuously taken into account. Laser scanning technology can even be used to generate welding programs automatically, depending on the size and shape of the part.
Automation of material transfers. Manually moving materials from one place to another takes up a considerable part of the working day. Work can be made more efficient with a storage and transport system where conveyors pick up the parts to be welded and the required jigs, and return the final assemblies and jigs to storage or on to production based on unique RFID tags. Product tracking is also continuous, allowing real-time information on product location and progress in the production process. At the same time, historical data can be stored to aid traceability and quality control. The solution requires a conveyor system to be set up in production, but a regional portal is also possible. In an area gantry, a gripper running on three axes moves the pieces within a freely defined area. As a system, it is more technical than a conveyor solution, but more flexible in terms of future layout and product changes: implementing these changes is mainly a programming issue, whereas a conveyor system often requires physical and heavy modifications in a similar situation.
Top-level controls. All the information required for production can be automatically routed to production from the company’s ERP system. The robotic system can be seamlessly interfaced with the in-house ERP system, and all pieces are placed directly into the work queue based on sales specifications.
Together or separately – which welding automation package is the right one to invest in?
By playing together, we always adjust the solution to suit each customer. While it is possible to implement these solutions individually, when making a decision, it is worth bearing in mind that the alternative to the above solutions is to do the work manually. In terms of cost-effectiveness, it is useful to include several parts in a project, so that the changes are implemented during the same project. When making this decision, it is also useful to consider the starting level of staff and the need for training.
We will always help you find the best solution, and our staff will be carefully trained and supported in the use of new technologies. Contact us if you are interested in more advanced welding automation solutions and let’s discuss further!