Machine welding - the future of efficient industrial production

Estimated reading time: approx. 8 minutes

TL;DR

• You will learn the main advantages of machine welding and why it is increasingly replacing manual welding.
• You will learn about the benefits of robotising the welding process and how it affects productivity and costs.
• You will discover what the preparation for the implementation of machine welding looks like and what issues are key in the process.
• You will understand the impact of automation on employee safety and the elimination of human error.
• You will find that machine welding is versatile and can be used in many industries.

Table of contents

- Introduction
- What is machine welding and why is it so important?
- Key benefits of machine welding
- Application of automation and robots in machine welding
- Machine welding in practice - example process
- Machine welding and lack of skilled workers - a step towards automation
- How to prepare for the implementation of machine welding?
- Compatibility with other production processes
- Is machine welding for every type of production?
- Examples of implementation results and figures
- Support and service - a prerequisite for maintaining high performance
- Practical conclusions and recommendations
- Summary
- FAQ

Introduction

Machine welding is today one of the key solutions for improving production processes in many industries. Increased automation, high precision and a significant reduction in human error are among the main reasons why more and more companies are opting for advanced welding technologies. In this article, we take a look at what exactly machine welding is, what benefits it brings to companies and how it can be implemented effectively. From the point of view of the machine and production line manufacturing industry, including Michale Automation, this issue is particularly relevant, as it translates into an optimal ratio between manufacturing costs and product quality.

After reading the article:
- You will learn what the concept of machine welding is all about and its main advantages.
- You will learn about the role of fully automated and robotic welding stations in modern companies.
- You will understand how to prepare for the implementation of machine welding and the key steps in the process.

What is machine welding and why is it so important?

Machine welding is the process of joining materials (usually metals) using machines or industrial robots. This technology enables welds to be reproducible and of high quality, regardless of production intensity or complexity. Unlike traditional manual welding, where efficiency and precision depend largely on the skills of the operator, machine welding ensures that the entire process is automated.

Why is this form of welding considered so important in modern industry? First and foremost, it is about reducing costs and the risk of errors. Manual joining of components is subject to variations in quality depending on the welder's fatigue, experience or even environmental conditions. Machine welding, meanwhile, guarantees stability, repeatable quality and less strain on workers.

Key benefits of machine welding

Machine welding is becoming a mainstay of modern manufacturing, particularly in the metalworking industry. There are many benefits that are leading companies to increasingly implement this technology in their facilities.

Higher precision and repeatability

Welding machines or robots operate according to defined algorithms and programmes. This translates directly into perfect repeatability of welds, which is impossible to achieve with larger-scale manual welding. This precision is important in industries where even minor deviations from the standard can result in serious quality consequences.

Cost reduction and time optimisation

For business owners, one of the key motivations for introducing machine welding is the reduction in labour costs and material consumption. Automation allows a higher rate of joining parts, thus increasing overall production efficiency. This makes it easier to remain competitive - both in terms of price and lead times.

Safety and improved ergonomics

The work of a welder can sometimes be dangerous due to high temperatures, fume emissions or radiation from the welding arc. The use of robots and machines removes some of the hazards and reduces the amount of time a person is in an area of potentially hazardous conditions. This means a higher level of health and safety in the plant and better conditions for the development of workers.

Application of automation and robots in machine welding

In order to fully exploit the potential of machine welding, factories are increasingly turning to industrial robots. Such solutions are offered, among others, by Michale Automation, which is the official distributor of robots from SIASUN - the world leader in industrial automation and robotics.

Welding robots as key to optimisation

Robotisation of welding is the next step in the development of machine technology. Welding robots can perform not only defined linear movements, but also complex interpolated paths, making them suitable for joining even the most complex structural components. Thanks to flexible software, the robot can be easily adapted to a specific application or changing production needs.

From a profitability point of view, the investment in a welding robot often pays for itself after only several months. Reduced material consumption, faster production times and a reduction in defective products are factors that clearly reduce costs. For companies that want to understand the potential savings, we recommend using the
ROI calculator for welding robotisation.

Implementation of robotic workstations

The process of implementing a robotic welding station depends largely on the type of machinery, the specifics of the production line and the planned level of automation. In practice, the biggest challenge lies in integrating the robot into the existing production environment. It is not only a matter of matching the kinematics of the robot arm to the required welding path, but also of appropriate communication with vision systems, sensors or even ERP/MES systems.

Companies such as Michale Automation offer end-to-end solutions - from the analysis of the welding processes, to the selection of the right equipment, to the installation and commissioning of the line. This provides the end user with a turnkey welding station, which saves time and avoids errors in the integration phase of the individual components. If you would like to check out our detailed offer on the robotisation of welding processes, see
robotisation of welding.

Machine welding in practice - example process

The implementation of machine welding can be presented in several main steps. In practice, each of these requires analysis and appropriate system configuration.

1. Analysis of production requirements
   - Determining the type of materials to be joined (e.g. black steel, stainless steel, aluminium).
   - Determination of shapes and dimensions of parts to be welded.
   - Examination of the quality of welds required by industry standards (e.g. welds in load-bearing structures).
2. Job design and configuration
   - Selection of machines and robots based on specific needs - including welding source power, type of fixtures and technology (MIG/MAG, TIG, laser).
   - Consideration of necessary health and safety precautions such as safety screens, fume hoods or safety sensors.
3. Integration with other systems
   - Connection of the welding station to transport lines providing infeed of workpieces and reception of finished products.
   - Application of vision systems for post-weld quality inspection.
   - Possible connection to ERP or MES systems to synchronise order data and performance reporting.
4. Testing and optimisation
   - Running a trial batch, observing weld quality, work speed, productivity.
   - Adjustment of power supply parameters, wire speed or other technical variables.
   - Training of staff in the use of the new position.

Machine welding and lack of skilled labour - a step towards automation

Many industries are currently facing a shortage of skilled welders. This is a significant problem for the industry, as traditional welding methods require experienced professionals who can do the job accurately. Meanwhile, machine welding, based on robots and automatic equipment, comes with a solution.

• Reduction in the need for specialised staff - some tasks are taken over by machines.
• Increased attractiveness of employment - machine operators often experience lower levels of stress and the company offers higher levels of health and safety.
• The possibility of retraining existing employees from the typically manual role of welder to robot operator, which can often be a significant professional benefit for the workforce.

How to prepare for the implementation of machine welding?

The implementation of new technology always requires careful planning and analysis. This is no different in the case of machine welding. Although automation offers many benefits, its success depends largely on how the company approaches the key stages of the transformation.

Process analysis and selection of appropriate technology

The first step is always to accurately define the company's needs. It is important to establish:
- What materials and products will be welded.
- What are the requirements in terms of tightness, strength or aesthetics of the joints.
- Do you need the multi-axis flexibility of a robot or will a simple linear welding station suffice.

In the next step, it is worth considering specific types of heat source (TIG, MIG/MAG, laser welding). Each of these techniques is characterised by a different degree of precision, different welding speeds and the size of the heated area.

Working with an experienced integrator

Not every company has the expertise and resources to design and integrate a welding station on its own. In such a situation, the most sensible solution is to work with specialists. Michale Automation, based on its experience in machine and line construction, can help design and commission a personalised machine and robot welding system, taking into account the individual company's goals and constraints.

This approach allows the entire process to be optimised and turnkey solutions to be implemented that minimise the risk of downtime. A service offering is also a worthwhile addition to consider, as regular maintenance not only ensures longer equipment life, but also maintains consistent performance. For more detailed information, when you want to find out more about
service and maintenance of posts.

Compatibility with other production processes

Machine welding rarely functions in isolation from other processes. It is usually part of a longer manufacturing chain: from part preparation, welding and post-processing to quality control.

What are the implications of this?
- If robotisation of only one stage is applied and the other stages are still carried out manually, there is a risk of a bottleneck.
- The integration of machine welding with other automatic machines (e.g. robots responsible for packaging or grinding) gives a multiplication of productivity.

It is therefore advisable to plan further development steps at the implementation stage. To get an idea of the full range of possibilities in the area of robotisation in the broad sense, we recommend
robotisation services.

Is machine welding for every type of production?

In broad terms, machine welding can be implemented in almost any area of industry where metal joining is needed. From the most complex machine constructions, to the automotive industry, to the white goods or agricultural sectors. The differences can be:

• Weld quality requirements (e.g. specific standards apply in the food industry).
• The use of difficult-to-weld materials, such as nickel or titanium alloys, which require non-standard parameters.
• Dynamically changing production conditions in design companies, where the final shape of welded components is not always reproducible.

Thanks to the flexibility of robots and modern welding sources, virtually any type of product can be adapted to machine processes. Of course, in many cases, implementation will require advanced programming and investment in additional infrastructure, such as rotary tables or grippers adapted to the specific shape of the component.

Examples of implementation results and figures

Let us analyse the simulation data of a manufacturing company in the metal industry that decided to switch from a manual welding method to an automated line with a welding robot.

• Cycle time for one weld → a reduction of 40% compared to the existing manual technique.
• Decrease in the number of quality defects by 60-70%, reducing costs associated with the correction and scrapping of defective components.
• Reduce annual labour costs by an average of 25% through a reduction in the number of overtime hours needed to fulfil orders during peak periods.
• Assembly speed increased by 30%, enabling new contracts to be signed with higher order volumes.

All these figures show that machine welding allows companies to grow and consolidate in the market - primarily by stabilising quality and managing costs more effectively.

Support and service - a prerequisite for maintaining high performance

Automation of welding systems is a significant capital investment. However, in order for it to remain profitable in the long term, it is necessary to systematically maintain the efficiency of the equipment.

Regular service and maintenance:
- They reduce the risk of unplanned downtime, which in the manufacturing industry is often the cause of serious financial losses.
- They guarantee that the set welding parameters are maintained, which translates into further repeatability and adequate weld quality.
- They help to identify possible defects (e.g. wear and tear on components, emerging software problems).

At Michale Automation, customers can benefit from a comprehensive after-sales service, including both warranty and post-warranty repairs. Qualified service teams are able to significantly reduce the unavailability of equipment. For more information on
service and maintenance of robotic workstations is available on the Automata Michale website.

Practical conclusions and recommendations

Based on the benefits listed and real-life examples of implementation, some of the most relevant recommendations can be made:

• Check the potential return on investment:
  Before you decide to switch from traditional manual welding to fully automatic welding, calculate the approximate costs and profits. Specialised tools such as ROI calculators to assess profitability can help you with this.
• Choose an experienced partner:
  Building and integrating welding workstations are complex processes. It is therefore good to have the support of a company that is familiar with automation and robotics - such as Michale Automation - at every stage.
• Ensure staff development:
  Even if most metal-welding processes are taken over by robots, you will still need specialists on your team - albeit in a slightly different role than before. Automation implementations, after all, involve programming and possibly modifying the robot's work.
• Schedule service and maintenance:
  Keeping welding stations and robots in top condition is a key factor in avoiding downtime. It is worth considering regular maintenance not as a cost, but as an investment in production stability and continuity.
• Think long term:
  Before ordering new production lines or deciding to expand existing ones, include system flexibility in your plans. Anticipate the need for additional functions or larger production capacities as your business grows.

Summary

Machine welding is not a temporary trend, but a clear direction of industrial development for the coming years. Automation and robotisation - thanks to their flexibility, precision and cost reduction - have become an almost indispensable part of the production process for any company that plans to compete in the global market.

There are many tangible benefits to implementing machine welding: from faster order processing, to stable quality parameters, to employee safety. However, in order to ensure that this phase of the transition to modern production yields optimal results, it is worthwhile to carefully analyse your needs and work with an experienced integrator.

If you are interested in the topic of full robotic welding, read the
a comprehensive range of automation products from Michale.

To better understand the potential for savings, check out
ROI calculator and see for yourself how quickly your investment in machine welding can pay off.

Also take advantage of the support of an experienced team in
servicing of robotic workstations.

You will also find other articles on industrial automation and process robotics on the Michale Automation blog. We encourage you to read them, subscribe to the newsletter and visit the company's social media. This way, you will always be up to date with the latest trends in the area of machine welding and your company will benefit from solutions that guarantee a quick return on your investment.

FAQ

How much does it cost to implement machine welding?
Implementation costs depend on the scale of automation, the type of robots used, the infrastructure and the weld quality requirements. The first step is always an in-depth process analysis and an assessment of the return on investment.

Is machine welding suitable for joining different materials, such as aluminium and steel?
Yes. Modern welding sources and industrial robots can be configured for different technologies (MIG/MAG, TIG, laser). Each is suitable for a different type of material, making it possible to weld a variety of metals.

Does the implementation of machine welding mean redundancies among welders?
Mostly no. Automation allows employees to take on new roles, such as robot operators or quality controllers. As a result, the company can increase efficiency and people develop in more forward-looking areas.