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Top 5 Ways to Automate Your Welding Processes

Updated: Feb 6, 2023

By Dylan Hardeman - January 27, 2023


Improving the welding process with industrial automation allows for increased productivity by optimizing difficult tasks. Industrial automation is no longer an optional element of manufacturing industries. To stay competitive, industrial automation must be considered to maintain the level of competitiveness with current manufacturing situations.


What is welding automation?

Welding automation is a form of automatic welding that uses electronically controlled tools and machines to complete welding applications with minimal human input. Welding fabrication industries include: automotive, aerospace, construction, shipbuilding, appliances, medical and energy.


How to Automate Your Welding Process?


Below, we have listed a few general ways to automate one's welding process for a more streamlined approach to the manufacturing process. Let's get started!


#1 - Job mode


Job mode allows the user to create and save multiple jobs with different welding and process parameters for each job ( wire feed speed, voltage, wire type, etc.). Fronius has the ability to create and save up to 1000 different personalized jobs. This eliminates the need to manually document the welding parameters.


#2 - Collaborative Robots


"Cobots" are designed to work alongside human operators. In cobot welding, the cobot is typically programmed to follow a predetermined path of set of instructions. Allows manufacturers to automate certain task while still maintaining a human presence on the factory floor. They are well-suited for tasks dealing with smaller parts and constant changeover.


#3 - Fixed Automation


Fixed automation robots are programmed to work one specific task repeatedly. Typically used for mass production or continuous flow systems such as in the automotive industry. Working one set of instructions repeatedly.



#4 - Programmable Automation


Most often controlled by a computer or separate control system. Also referred to as "batch automation," meaning products are made in batch quantities from a few dozen to a few thousand units at a time. Each time the robots must be reprogrammed to adjust to the new batch. Programmable automation systems are best used in low variety and medium to high production. A good example of programmable automation are CAD/CAM systems or CNC operations.


#5 - Flexible Automation


Flexible automation typically used in high variety - low production processes. Each piece is given different instructions and pathways to complete the welds for the product. Changeovers from different parts occur more quickly in flexible automation situations because they are transferred through the control system.


#6 - Instant Automation


Instant or "point cloud" automation is a form of flexible automation. It uses 3D profiles or point clouds to determine the part shape, from there parts are recognized from the database. Operators can then pick and place welds. Instant Automation is most preferred with high variety - low to medium production. Industries most involved are steel construction, shipbuilding, and fencing/railing.

Instant programming, done via 3D laser scanners, has become a more recent advancement to the fabrication industry allowing for more precise and time saving improvement with its real world measurements.


Result


Fabrication and automation each have their own challenges, combining both of them can lead to promising outcomes of success. We hope that you found the information valuable and that you're now ready to take the next step in your journey. If you're ready to take action, download our free guide to instant programming!



Thank you again for your interest, and we look forward to helping you achieve your goals.

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