Welding Robots Can Offer Benefits for Smaller Shops | MillerWelds

Positive results with welding robots

Robotic welding offers numerous benefits for companies of all sizes — from improved productivity and weld consistency to lower costs for production, labor and materials. When implemented correctly, robotic welding systems also help companies gain a competitive advantage. More than ever, smaller shops are beginning to make the investment in automation and realizing positive results.      

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There are, however, various considerations to make before adding welding robots to the shop floor. Selecting the right system, assessing the available facility space and training welding operators properly are just a few factors that can help companies gain the best efficiencies and the best payback.

What are the advantages of robotic welding?

Robotic welding systems offer consistency and repeatability that can lead to significant improvements in productivity and finished part quality. That better quality also helps reduce the time and money spent on rework. In addition, these systems can lower production costs by reducing waste and labor requirements. For example, a welding robot has the ability to lay down the same amount of weld metal each pass with limited supervision, eliminating the issue of over-welding and the associated filler metal waste and cost.

Such benefits translate to many applications in both large and small shops. Yet the investment in even one robotic cell in a smaller shop may result in welding automation taking over a higher percentage of the total welding output, for a potentially greater return on investment (ROI).

Likewise, while larger companies may have more resources to draw on when adding welding automation, smaller shops can potentially gain greater flexibility while adding automation. In some cases, the owner may frequently be on the shop floor, and employees may wear multiple hats. The outcome is a collaboration that can result in greater employee buy-in on the purchase and an innovative approach to gaining the best efficiencies. Still, a good rule of thumb for any shop considering robotic welding — small ones included — is to fully evaluate the welding operation and parts before making the purchase.

Key considerations for welding robots

When considering robotic welding, shops should ask the question “What are our pains?” By identifying goals before starting the process, the company can determine if welding automation is indeed the right solution. Those goals may include improved throughput, increased welding quality or simplified training for welding operators. Once a company identifies the challenges and goals, considering the following can help:

Robotic welding cell cost

Knowing the benefits welding robots can provide can offer a better understanding of what the ROI expectations are. ROI estimates should consider the labor rate of each shop and how much time welding automation might save. Estimates should also include the ratio of machine uptime to downtime for part and fixture changeover. Some shops may have a single part with enough volume to justify a robotic system. In other shops, it may be necessary to combine multiple parts to get the needed volume for ROI purposes. In those cases, grouping by family of parts (like parts of different sizes, for example), can help improve efficiency and save on downtime for fixture changeover. 

Physical space and facility modifications

The robotic welding solution needed may require a weld cell that is larger than the area available. The need to expand or modify the space to accommodate a robotic welding cell adds to the costs and can greatly impact ROI, so it’s an important consideration to keep in mind. 

Part design

While parts don’t need to be perfect, they do need to be repeatable. If there is a gap in a part, it needs to be a repeatable gap so the system can weld it the same way each time. When there is too much variability in the parts, it can lead to more downtime for adjustment or rework.  

Part workflow

The workflow for robotic welding will likely be quite different than the workflow for semi-automatic orders, which can be changed more easily and produced in smaller batches. A robotic system typically produces three to five times the number of parts in the same amount of time. Therefore, it requires the throughput to be more consistent throughout the entire process. 

Weld cell supervision and training

This is one of the most important factors to operate a successful robotic welding operation — especially for first-time users and smaller shops where technicians may not be in-house. Unfortunately, it is also often one of the most overlooked factors. The initial training on a robotic welding system is critical. Many welding manufacturers offer on-site training to help with installation, basic programming and user training. This training can help prevent common issues that affect system performance, such as incorrect liner and/or gun installation. It is also important to conduct ongoing training. The features and functions of robotic welding cells can change, so it’s important to remain up to date on them to make the most out of the investment.

Advancements can make it easier

There are technologies and solutions available that make it easier and more feasible for smaller shops to add welding robots. Pre-wired and pre-assembled robotic weld cells are one such example. In fact, some preconfigured systems can be up and running within a matter of hours.

Offline programming can also provide benefits for companies. It allows shops to program parts and design fixtures before the welding actually takes place in the weld cell. This feature offers the ability to remove any mistakes before material is cut for fixtures and can reduce machine downtime for setup. The result is greater uptime and throughput that is consistently high.

Several options in robotic MIG gun technology and peripherals can also help increase productivity and reduce downtime for consumable changeover, further increasing the ROI for smaller shops. A robotic cleaning station (or reamer), for example, removes spatter from front-end consumables without the welding operator entering the cell. This spatter removal helps consumables last longer and reduces downtime for maintenance.

Front-loading liner systems available for some robotic welding guns are also designed to minimize downtime and reduce issues with wire feeding. Proper liner installation is critical to guiding the wire through the power cable and up to the contact tip. Improper liner installation, which includes trimming the liner too short or having a liner that is too long, can lead to a number of issues, including bird-nesting, poor wire feeding and debris in the liner. Front-loading liner technology can save significant time in changeover. It allows operators to easily change the liner at the front of the gun without removing the gun from the robotic system. Some front-loading liners also have a spring-loaded module to accommodate for up to 1 inch of forgiveness for improperly trimmed liners.

Become more competitive with robotic welding

In the realm of metalworking, choosing the right welding method and equipment is crucial to meeting project demands efficiently. Among the myriad of welding techniques available, Metal Inert Gas (MIG) welding stands out due to its adaptability and ease of use. Whether you're a seasoned welder or just embarking on your welding journey, understanding the benefits of MIG welding machines can significantly enhance your craftsmanship and productivity. This article delves into what makes MIG welding machines indispensable, exploring their definitions, various advantages, classifications, and sourcing tips to meet user needs effectively.

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Efficiency and Productivity in MIG Welding

MIG welding, an acronym for Metal Inert Gas welding, is a method that involves feeding a continuous solid wire electrode through a welding gun into the weld pool. A gas, typically argon or CO2, is also fed through the gun, shielding the weld from contaminants in the air. This process results in a strong, clean weld. Unlike the stick welding process that requires you to stop to replace used electrodes, MIG welding's continuous wire feed reduces interruptions, facilitating a more efficient workflow.

Anecdotally, consider the case of Jake, a small automotive repair shop owner. Jake's projects demand quick turnarounds and high-quality welds. With manual welding techniques, he often faced inefficiencies. Switching to MIG welding machines allowed him to meet customer demands swiftly, thanks to the seamless welding process. This change drastically improved his productivity and customer satisfaction.

Key Advantages of MIG Welding Machines

MIG welding machines offer several advantages, making them a preferred choice for many welding tasks. Firstly, their simplicity and ease of use suit both beginners and experienced professionals. With minimal setup time and straightforward operation, beginners can start producing quality welds quickly. Meanwhile, experienced welders benefit from less fatigue and increased speed in completing tasks.

Additionally, MIG welding machines are versatile, capable of working on diverse materials such as aluminum, mild steel, and stainless steel. This versatility is particularly valuable in industries ranging from automotive repair to heavy constructions, where different materials are often used.

Another advantage lies in the quality of the welds. MIG welding produces cleaner and aesthetically pleasing welds with minimal spatter and post-weld cleaning required. This is possible because the shielding gas prevents air contamination, resulting in robust and secure joints. For example, Laura, who works in a metal fabrication shop, shares how MIG welding enhanced her projects' final appearance significantly without additional polishing efforts.

Classification of MIG Welding Machines

MIG welding machines are classified based on their power source and portability. Common classifications include:

• Transformer-Based MIG Welders: These are traditional MIG welders characterized by their robustness and longevity. They are ideal for heavy-duty welding tasks.
• Inverter-Based MIG Welders: These newer models are appreciated for their compactness, energy efficiency, and precise control over the welding parameters. They are perfect for delicate works and environments where space is a constraint.
• Portable MIG Welders: Lightweight and versatile, these machines allow welders to transport their equipment easily, ideal for on-site maintenance and repairs.

An example from a well-known manufacturer illustrates these classifications' real-world applications. Their line of portable inverter-based MIG welders, for instance, provides flexibility and power control for field work—an essential aspect for construction contractors handling various environmental conditions.

Key Considerations for Sourcing a MIG Welding Machine

When sourcing a MIG welding machine, consider key factors that align with your specific welding tasks and workspace conditions. Start by assessing the machine's power needs concerning the materials and thicknesses you intend to weld. Machines with adjustable settings are beneficial for handling a wider range of tasks.

Next, consider the duty cycle, which indicates how long a welder can operate before needing to cool down. A higher duty cycle is preferable for extensive projects to avoid interruptions. Also, prioritize reliability and user support. Opting for equipment from a well-reputed manufacturer often ensures better customer support and replacement parts availability.

Moreover, factor in the ease of obtaining consumables like wire and shielding gas. Lifelong costs are crucial too. Thus, comparing warranty terms and conducting a cost-benefit analysis based on long-term usage can help in making informed purchasing decisions.

In a notable instance, a local fabrication company invested in durable inverter-based MIG welding machines despite the higher upfront cost. They found the reduced energy costs and minimal maintenance needs significantly beneficial, proving a rewarding financial decision over time.

Conclusion

Opting for MIG welding machines aligns with the need for efficient, versatile, and high-quality welding solutions. From a beginner looking to advance career skills to a professional seeking reliability and efficiency, MIG welding offers immense benefits. By understanding the differences between machine classifications and considering thoughtful sourcing tips, users can select welding equipment that best suits their needs, ensuring successful project outcomes.

Frequently Asked Questions

Q: Can MIG welding be used outdoors?
A: While MIG welding is typically best suited for indoor use due to wind disrupting the shielding gas, using wind-shields or gas mixtures with CO2 can enable outdoor applications.

Q: Is MIG welding suitable for thin metals?
A: Yes, MIG welding is highly suitable for thin metals due to the control over heat input, which minimizes the risk of burn-through.

Q: Do MIG machines require special training to operate?
A: Although MIG welding is easier to learn compared to other methods, basic training is recommended for understanding safety procedures and optimal machine settings.

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