Budgets, Training, and Beyond: Gaining Success with Robotic Welding
BY JUSTIN CRAFT, field tech support specialist, Tregaskiss, Windsor, Ont., Canada. Reprinted with permission: The AWS Welding Journal Set realistic goals for completing installation of robotic weld cells and don’t rush or overcomplicate the process The potential advantages of robotic welding are well known — increased productivity, improved quality, and greater cost savings compared to semiautomatic welding. But how do companies best implement this technology to gain these benefits? And how can they ensure a quick return on the investment (ROI)? Simply stated, planning. More preparation upfront helps minimize the cost and time for correcting errors in the robotic welding system once it has gone into production. From the welding power source to the robot or weld process to the gun and consumables, each component should be thoroughly researched to make sure it is feasible to operate in the weld cell — not just on paper, but in reality — Fig. 1.When implementing a robotic welding system, every component should be thoroughly researched to make sure it is feasible to operate in the weld cell — not just on paper, but in reality.
- Implementing the wrong equipment in a robotic welding cell can lead to spending more money than is required. Be sure the power source, robotic GMAW gun, and consumables are rated for the application. Doing so helps minimize the risk of premature equipment failures that can lead to unplanned downtime and costly equipment replacement. For example, if a company selects an air-cooled system, but actually requires a water-cooled system for the application, it could incur unnecessary costs to repair or upgrade a failed robotic GMAW gun system that cannot handle the heat.
- Underutilizing the robotic welding system can prevent companies from realizing their full productivity potential. Robotic welding systems should be programmed to maximize the arc-on time during the weld process cycle. In some cases, it may be possible to have fewer robots that weld for slightly longer cycles. This helps drop the initial implementation costs.
- Underutilizing available labor can also hinder productivity. While companies should take care not to overload operators, it’s important to balance manpower in the robotic welding process so that employees are efficient and busy at the same time. If an operator is idle waiting for the weld cycle to complete, there could be room for process improvements by allocating labor to other activities near the weld cell.
- Poor tooling design can impede quality. Thoroughly plan the tooling design and understand how the parts being welded will impact it. Different parts and materials react differently to heat and may draw, flex, or bend during the welding process. Factor in how much heat a given weld sequence generates. The tooling will have to be designed with this in mind. If possible, design tooling to permit welding in the flat or horizontal position with appropriate robotic GMAW gun access. This allows for faster and more consistent results. Finally, remember, less expensive tooling may be attractive when looking at upfront costs, but it can be a pitfall later if it doesn’t meet the demands of the job.
- Overlooking activities outside the robotic weld cell can be detrimental. Plan for part inspection and cosmetic rework, as well as the final stages of palletizing the product if that is part of the operation. Some of these processes can be automated or manual labor driven. These are key stages in a robotic welding operation that can quickly become bottlenecks that cause the entire process to slow down. These bottlenecks can also add unplanned manpower or equipment costs, which can become expensive.