AUTOMATION AND ROBOTICS
By
EWM HIGHTEC WELDING UK Ltd .
In the production process , welding is among the most complex of procedures and it is becoming harder and harder to find suitable personnel for the job . Can this problem be solved by automating processes ? Can ( and should ) robotic “ colleagues ” replace experienced welders ?
The automation of manual welding is a complex , multi-step process . Welding and joining technology companies are struggling to find suitable skilled workers . Many manufacturers are confronted with a dilemma : a lack of welding specialists and increasing labour costs on the one hand , and increasing requirements in terms of the quality , flexibility and efficiency of welding processes on the other . As a result , companies are increasingly relying on the automation of processes and the use of robots .
What used to be commonplace , primarily in the automotive industry and large-scale production in past decades , is also becoming increasingly important to small and medium businesses in a wide variety of industries . This is because automated welding processes are no longer just economically viable for large corporations . Automation promises precise repeatability with consistent weld seam quality , process reliability and increased productivity thanks to minimal set-up and auxiliary process times .
Basic requirements for the automated process
If welding processes are to be automated , there is more to do beforehand than just determine which components will be produced and with which relevant geometries processes need to comply . Specifications on batch size , tolerances and the required welding procedures are also important .
“ It is often essential to first gain an understanding of the process . A robot can ’ t compensate for a change in position , but a welder certainly can ,” remarked Max Lautenbach , Acting Application Engineering / Automation Manager , EWM GmbH . “ The welding equipment therefore has to be just right and this usually involves greater effort .”
Along with automation come changes to all the processes involved . Processes , both upstream and downstream of the welding cell , must also be adapted . For example , enough components from pre-production must be available so that the system can run
Automated production of the base support with two EWM AMT welding torches in parallel . To reduce distortion and increase welding speed / process reliability , forceArc puls has been used .
THE PATH TO AUTOMATION
What are the basic requirements for automating welding processes and using cobots on the shop floor ?
“ When automating welding processes , it is essential to view the system holistically . EWM outlines how to prepare your company for automated welding .”
Left : Application of wear protection on pump protection valves via surfacing .
at optimal capacity . There are also greater requirements in terms of component precision . Welded parts then need to be transported away and stored at the right time to avoid a process bottleneck . Personnel available on-site also need to be considered . “ Completely untrained employees cannot operate a robot system ,” explained Andreas Euen , Managing Director , EWM-EUEN GmbH . “ Robots reduce the overall need for personnel , but employees who know how to program a welding cell are needed on-site to automate processes .”
Cobot versus welding cell
Collaborative robots ( cobots ) are fashionable , and they are increasingly being used in the welding technology field . Their main advantage lies in straightforward system operation . A cobot can easily be trained on-site and then repeat the processes that it has been shown . Complex programming is not required , but teaching-in should be carried out by specialist staff . Cobots boast a good priceto-performance ratio , which also makes them suitable for use by smaller companies .
Safety must also be considered as the welding process comes with a multitude of risks from potential welding sparks , the generation of hazardous radiation , electrical hazards and the creation of harmful substances . This means that “ hand-in-hand ” work with a cobot with a burning arc is hardly ever possible .
Compact welding cells , which are also costefficient , are attractive to smaller companies . XQbot welding cells from EWM , for example , are a good introduction to automation . The driving force of these cells is the CRX robot from FANUC , which is comparable
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