Robots are essential tools in the manufacturing industry. In a digitalized age that has mainly shifted its focus from a hands-on approach to manufacturing to machine-based manufacturing, robots are proving to be useful tools. To work properly, they need to be connected to end effectors at the wrists. Robot end-effectors or end of arming tool (EOAT), make a variety of actions possible by the robots such as welding.
A welding robot arm is an automated welding process that increases accuracy, efficiency, reduces the time used to complete projects, and makes a working environment generally safer.
Many companies and businesses have opted to use welding robot arms in recent years for various reasons including high yields and quick manufacturing processes.
How Does Robotic Welding Arm Work?
A series of steps must be incorporated for a welding arm to work. The right programming tools must be set in place for an automated welding robot to be fully functional.
For a robot welding arm to be effective and operational, it must first be able to move. The movements will differ based on different welding arms but there are two types of arms i.e. rectilinear and articulating versions.
Rectilinear types of arms can move in at least 3 dimensions while participating versions can move in more planes.
Welding arms use sophisticated communications systems that cause them to respond based on the instructions. Usually, for the welding process, the arm has a high heat emitting torch that melts the metal, making the welding process possible.
When a manual approach is used, people’s lives are often in danger because welding often requires dangerously high temperatures. The use of robot welding arms reduces the number of people who are exposed to high temperatures and has therefore made the process relatively safer.
The robot welding arm also comes with automated safety systems that ensure the safety of those who have supervised the processes and set up controls.
What Is The Process Of Robotic Welding Arm
Welding is not a simple job. It is a highly sophisticated process that requires highly trained personnel to operate. Without the proper training or skills, the processes will not operate smoothly. Those weld without the proper skill or education may cause harm or potentially place their lives and those of others at risk.
A robot-based welding system, however, takes much of the burden off. The welding industry is inadequately staffed making the workload more than the workers can bear. The welding arms have taken a huge load off the backs of workers and company owners alike.
An automated process guarantees accuracy, increases production, reduces manufacturing time, and promotes safety. There are a wide variety of processes available for robotic welding arms.
Arc Welding
It is a common type of robotic welding. It mainly focuses on generating extreme heat with highs of up to 6500 Fahrenheit. The process involves the joining of molten metal parts together and ensuring that they solidify in a stable position after they have cooled. This kind of welding arm is suitable where there is production in large quantities and a need for metals to be accurately joined.
Resistance Welding
This is a great method to use for cost reduction. The process uses electric currents to melt metal which forms a pool that passes between two metal bases. The melted metal will join the metallic pieces together.
Spot Welding
Some projects require unique welding forms. In industries such as the automotive industry, where pieces forming the automobile bodies are joined together, electric current is not used because some materials are resistant. The solution of spot welding is that it uses resistance welding. This connects the thin pieces of metal in a single spot.
There are other forms of welding as such as;
- Tig Welding
- Plasma Welding
- Mig Welding
- Laser Welding
Benefits Of Robotic Arm Welding
There are so many advantages that arm welding provides to companies.
Efficiency
When people weld, there are prone to be weaknesses that will slow down production. People need breaks while robotic systems can work 24hours a day. Robots do not get tired, they do not need a five-minute break and their output is consistent both in quantity and quality.
Safety
Exposure to the kind of heat that is required in welding is dangerous. A welding arm means that the amount of exposure people have to the heat directly is minimal. The systems also provide automatic safety features which are have played a huge role in creating a safe environment for workers.
Accuracy
Since robots are controlled by programs, they work with accuracy. Even the most skilled humans are prone to err while robots can repeat work without flaws and this is one of the reasons why robots are a preferred option.
Waste
More accuracy means less waste. Robots work with such precision, that often doesn’t leave any room for error. Few materials need disposal due to errors made.
Disadvantages Of Robotic Welding Arms
Costly
Robots are not cheap which is understandable considering the kind of work they do and the quality they produce. Robotic systems require special programming which requires skill to operate. Hiring an expert adds to the cost of buying the robot.
Feasibility
Robots are a great investment but they may not be a feasible or a sensible choice for every company. A small business may not have a large volume of production making such an investment unreasonable. The returns may also not justify the cost.
Flexibility
There are things that robots cannot do, sophisticated as they are. It is easier to customize products when a human is operating than with a robot. Changes for robots would mean changing the programming. This takes time and also requires skill. Whereas with a human, all it takes is simple instructions to make the needed change.
Conclusion
Robots are revolutionary inventions that have forever changed the production industry. They have simplified the lives of many, reduced the risks that were involved with the production. Many businesses have experienced growth because of the use of welding arms. A robotic welding arm is a wise investment for any business that desires to grow.
