1
www.hse.gov.uk
automation & robotics
robotic welding
maximum productivity, simple integration, low operating costs:
the answer to weld quality optimisation
several traditional manufacturing methods have been automated over the years in response to several influencing factors, such as; supply versus demand, product integrity considerations, access to a skilled labour pool and maintaining competitive advantage. welding falls into this category, and as a manufacturing process in today’s current climate, automated robotic welding is gaining in both popularity and progression.
t
he automotive and aerospace sectors have traditionally been the advocates of automated welding. since welding is one
of the most effective methods of joining metal, both industries have plentiful need for it - specifically, miG and arc welding. recently, however, there has been an increase in the adoption of the process across other sectors. For example, factors such as speed of execution and cost effectiveness are championing its integration into high-output production facilities.
a move towards flexibility mass production of multiple product iterations and mass customisation deliver significant challenges to manufacturers who adopt traditional hard automation principles (i.e. processes that are fixed). as such, we are now seeing a move towards flexible production systems. a flexible approach enables businesses to respond quickly and efficiently as consumers behaviours diversify, demand evolves and market trends fluctuate. the beauty of flexible automation systems is the
ease of which a designated programme or application can be changed according to a specific manufacturing requirement. in addition, the footprint of many standard welding cells, which are relatively small, means that substantial reconfiguration of an existing operational footprint is not necessary. Whilst some consideration
surrounding whatis to be achieved and whereis imperative, the limitations that might apply to hard automation do not exist. in fact, standard welding cells afford several returns: simple automation capability; optimal process reliability; system availability; and system flexibility. if we consider the process of welding itself, the
manual application of a weld is one that requires both skill and dexterity to complete. in mass production welding, a material bond must be consistently executed to alleviate both costly recalls and wastage, as well as deviations in product shape and size. it has been widely acknowledged that robot process automation delivers a level of repeatability and accuracy that cannot be sustained by manual means (i.e. by a human), and, as such, product integrity and quality output are one of several key considerations when deciding to adopt automation.
safety through automation Health and safety is another area where automated welding shines. according to the Health & safety Executive, in reference to welding, ‘occupational lung disease, including lung cancer, is the most common health risk, but welding can also affect the eyes and skin. there is also a significant risk from asphyxiation when welding in confined spaces’1
make for pleasant reading, and aside from the
risk to employees’ health, businesses must also consider the financial risks associated with compensation pay-outs and fines. automation is the logical solution. ‘Employ’ a
robot to undertake risky welding activity and redeploy operators into other areas of your business, where they can add value and apply skills to high value applications/tasks. the automated system is then able to operate 24/7, if needed, and presents the opportunity for a business to expand upon an existing portfolio of weld capabilities, through the introduction of new applications, even break into new markets.
automated robotic welding unlike a hard manufacturing asset confined to a defined product iteration that cannot easily be adapted, standard cells are setting... well... standards for the future of manufacturing. Welding is conceivably one of the more complex manufacturing processes and arguably the least understood, but the benefits are immense. robotic arc welding technology offers everything that is needed for automation in the age of industry 4.0, for beginners and advanced automation experts alike.
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44 april 2021 | FactorY&HanDlinGsolutions
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