Integration of welding robots into an existing production line - key aspects of welding technology

Estimated reading time: 9 minutes

TL;DR:

• Welding technology ranges from MIG/MAG and TIG to laser welding and resistance welding.
• Robotised welding increases the efficiency and repeatability of the process, as well as improving occupational safety.
• Implementing a welding robot requires a needs analysis, selection of the appropriate technology and integration into an existing line.
• The support of an experienced partner (design, installation, service) minimises risk and accelerates the return on investment.
• By investing in modern robots, costs can be significantly reduced, profitability can be increased and consistent product quality can be maintained.

Table of contents

- Introduction
- Variety of welding technologies - from traditional to fully automated methods
- Robotic welding - why implement it?
- How to plan the integration of a welding robot into an existing line?
- Integration of welding robots in practice - important areas to consider
- Examples of applications and financial benefits
- Why use Michale Automation's support?
- Practical lessons from implementations - what to keep in mind?
- Summary - Welding technology for the future of your production
- FAQ

Introduction

Welding technology plays a key role in the manufacturing industry, providing durable and precise joining of metal components in a variety of production processes. Increasing automation and advances in robotics mean that more and more companies are opting for robotic welding solutions. In this article, we take a look at what modern welding technology is, why you should think about integrating welding robots into your existing production line and how to implement this solution step-by-step to achieve maximum efficiency and repeatability in the process.

Among other things, you will learn:

• What types of welding technologies are most commonly used in robotic processes.
• What to look for when planning the integration of a welding robot into your production line.
• How Michale Automation supports companies in the implementation of welding automation.

After reading the article, you will understand the benefits that the implementation of robotic solutions in welding processes can bring and how to prepare for the integration to reap the full benefits.

Variety of welding technologies - from traditional to fully automated methods

Welding technology is a wide range of material joining methods, subject to continuous development. Depending on the needs and quality requirements, a suitable welding process can be selected to achieve high strength and precision of the joint. The main types of welding technology are:

Gas-shielded arc welding (MIG/MAG and TIG)

- MIG/MAG - These methods involve the use of both active (MAG) and inert (MIG) gases to protect the weld pool. They are particularly popular in series production, not least because of their high productivity and versatility.
- TIG - a method of welding with a tungsten electrode shielded by a noble gas (usually argon). It is used in industries requiring precision, such as automotive, aerospace and stainless steel structures.

Spot welding and resistance welding

- Spot welding and resistance welding involve the use of pressure and heat energy to join components at the point of contact. Their popularity is due, among other things, to their short cycle times and low operating costs, especially for high production volumes.
- They will prove useful in automotive applications, for example, where it is important to quickly join steel or aluminium sheets at specific points.

Other advanced welding methods

- Welding of friction elements - bonding of materials by the generation of high temperatures through friction between surfaces. A method suitable for joining metals with different physical properties.
- Laser welding - the process uses a laser beam, ensuring precision and the ability to weld thin sheets with a small heat-affected zone.
- Brazing and surfacing - They are useful, for example, when it comes to regenerating surfaces or bonding materials with different properties.

The choice of a particular method depends on the material, its thickness, quality requirements or production volume. How you want to integrate the method into your existing production line is also key.

Robotic welding - why implement it?

Welding robotisation is used today by companies that want to increase productivity, improve product quality and standardise production parameters. Thanks to modern technologies, robotised welding workstations almost completely eliminate errors due to the human factor and, with proper planning of the process, further reduce time and production costs.

• Greater process repeatability - The robot always welds at the same speed, maintaining constant position and arc parameters. Once the optimum settings have been determined, you can count on identical quality for each subsequent joint.
• Reducing gaps - Thanks to precise control, robots minimise the risk of incorrect joints. Fewer faulty pieces mean less material loss and lower costs.
• High flexibility - The welding programme can be changed at short notice to accommodate new design guidelines or the specifics of a different workpiece.
• Enhanced safety - The work of a welder in many cases involves exposure to intense radiation, high temperatures and harmful fumes. Robotisation allows people to be relieved and focus their attention on more demanding engineering tasks.

Before implementing a welding robot, many companies are concerned about the high investment costs. However, it is worth pointing out that the return on investment may be quicker than it seems, especially in a repetitive and high-volume production environment. In this context, available ROI calculators are helpful, e.g. ROI calculator for welding robotisation, which allows the financial benefits to be estimated in the short term.

How to plan the integration of a welding robot into an existing line?

The implementation of a robotic welding station is a complex process that should be carefully planned. Here are some key steps to follow as you prepare for integration.

1. Needs analysis and technology selection

The first step is to identify the objectives the company wants to achieve by implementing welding robotisation. It is worth asking yourself the questions:

• Are we looking to increase productivity and the number of items produced?
• Is high repeatability necessary due to the advanced quality process?
• What materials will be welded and in what quantities?

Based on these answers, it is determined which welding technology (e.g. MIG/MAG, TIG, spot welding) will be optimal. A further consideration is the evaluation of the existing infrastructure and a complete analysis of the bench layout.

2. solution provider selection and consultation

A good technology supplier, such as Michale Automation, will offer not only the equipment itself, but also advice on its selection, installation and integration into the existing line. It is important that the supplier uses state-of-the-art robots and control systems, tailored to the requirements of the production in question. An example of this would be SIASUN-branded robots, which enable fast and precise welding in different positions and conditions.

3. bench design and integration with IT systems

Once a solution has been selected, and prior to the delivery of the equipment, it is useful to develop a detailed design of the workstation including:

• Positioning of the robot in line and ergonomic handling by personnel.
• Safeguards (light curtains, guards) related to human safety.
• Integration with existing IT systems - including MES or ERP systems if real-time tracking of welding parameters is a priority.

For more advanced processes, such as multi-station production lines, welding robots can work in conjunction with vision systems that help with precise positioning and automatic correction of the welding trajectory.

4. installation and commissioning tests

Once the workstation is physically assembled, it is time for commissioning tests. During these, the quality of the joint, the rate of operation, the safety parameters and the stability of the production cycle are verified. The aim is to achieve the envisaged performance without compromising on the quality and safety of the work.

5. training and service support

An element that is often underestimated, but extremely important, is the training of operators and the engineering team. Correct operation of the welding robot and the ability to react quickly to potential faults is essential for maintaining production continuity. It is therefore advisable to take advantage of comprehensive service care, which includes not only repairs, but also regular maintenance and possible software modifications. In this context, it is worth taking a look at service and maintenance offersto provide professional support at every stage of operation.

Integration of welding robots in practice - important areas to consider

Achieving success in robotic welding requires developing synergies between different areas of the company. The following are some of the elements that are usually crucial to the success of the whole endeavour.

Quality of materials and preparation of details

A welding robot, even the most technologically advanced one, will not produce the expected results if the prepared parts are of poor quality or in the wrong position in the line. This is why it is so important to:

• Ensuring consistent quality of materials (e.g. properly cleaned surfaces).
• Accurate calibration of chucks and clamping devices.
• Reduction in error tolerance when cutting or bending workpieces.

Transport automation and cooperation with other robots

A robotised welding station becomes even more efficient when it cooperates with other automation systems. This can include, for example, a palletising robot (to facilitate the collection of finished parts), a painting robot or a robot that arranges small components in the correct sequences.

• Thanks to intelligent planning of the material flow, the successive stages of production complement each other seamlessly.
• It is also possible to extend an existing line with vision systems that verify correct assembly before the workpiece is released for welding.

Integration with MES and ERP systems

Advanced companies often use MES (Manufacturing Execution System) or ERP (Enterprise Resource Planning) systems to comprehensively manage production. Connecting a robot to such a platform brings many advantages:

• Ability to monitor key parameters in real time (e.g. welding speed, material consumption).
• Analysis of the performance of individual shifts, lines or weld nests.
• Easier inventory management and control over material delivery schedules.

Examples of applications and financial benefits

Many companies are opting for robotic welding because of the long-term benefits. Here are some specific examples:

• Automotive sector: Here, speed and precision are key. The welding robot integrates with the line to make hundreds of identical joints a day in a cycle of a few seconds. In this industry, reducing shortages and speeding up production by up to a dozen per cent can translate into hundreds of thousands of zloty in savings per year.
• Manufacture of steel structures: Large structural components (e.g. masts, trusses) require durable joints and adequate weld penetration. By automating the process, the consumption of auxiliary materials is slowed down and a more predictable working rhythm is achieved.
• White goods industry: Manufacturers of household appliances are concerned with aesthetics and reliability. The robotised welding of fronts, housings or internal components reduces the risk of microporosity or colour changes due to unstable manual parameters.

Each of the aforementioned industries is focused on reducing costs and increasing product quality. Welding robots are excellent at achieving both objectives, especially when the integration is well thought out and based on a sound cost-effectiveness analysis.

Why use Michale Automation's support?

Michale Automation specialises in the construction of machines and production lines, as well as industrial automation - including the implementation of robotic workstations for welding, packaging or painting. As an official distributor of SIASUN robots, we offer our customers access to advanced solutions that stand out:

• Versatility: SIASUN robots perform well in the welding of steel components, aluminium and many other alloys, as well as in handling, packaging or operating machinery.
• Simplicity of integration: thanks to modern software and compact design, the robots can be fitted relatively easily into an existing line.
• High ROI: rapid return on investment with well-planned production.

For detailed information on how we solve the automation process comprehensively in our company and how we adapt robots to specific production needs, please see the section on robotisation of welding. It is also worth taking a look at the general offer of robotisation services, where we present example implementations.

Practical lessons from implementations - what to keep in mind?

Before you make the final decision to integrate a welding robot, pay attention to a few practical points. The following points can help you achieve satisfactory productivity and quality more quickly:

• Reliable definition of quality requirements: if the welded construction will be subjected to stringent standards or inspections (e.g. in the food or automotive industries), detailed quality tests must be planned.
• Close cooperation with the maintenance department: service technicians and engineers must be able to diagnose problems and solve them without undue delay so as not to interrupt production for an extended period of time.
• Development of staff competence: in many companies, it is noted that robot operators, with a better understanding of the welding process, are able to make minor adjustments to programmes, which instantly translates into maintaining high production stability.
• Maintenance and upgrading of the stand: in the long term, it may be necessary to refresh components, update software or improve safety systems. A well-thought-out service strategy ensures that the line operates with equal efficiency for many years.

Summary - Welding technology for the future of your production

Welding technology, especially in its robotic form, continues to evolve, becoming increasingly versatile and business-friendly. It is the perfect solution for anyone looking to reduce costs, increase productivity and ensure high quality and repeatability of manufactured parts.

Key information to bear in mind:

1. Set production targets and quality requirements before implementing a new welding system.
2. Make a choice of welding method (MIG/MAG, TIG, spot, etc.), taking into account the type of material and the specifics of the product.
3. Carefully analyse the existing infrastructure and optimise the layout to integrate the stand into the entire line.
4. Benefit from a comprehensive offer from an experienced partner - from design to installation to service.
5. Provide staff training and a well-thought-out maintenance policy to take full advantage of the benefits of robotisation.

Every company has its own needs and challenges. With proper planning, the selection of reliable suppliers and a focus on material quality and correct parameterisation, the implementation of robotic welding can translate into real savings after just a few months. If you would also like to look at other processes that can be automated, you can take a look at an offer for the robotisation of repetitive production.

Summary
Robotic welding workstations are the future for many industrial companies that want to maintain and strengthen their market position. Welding technology offers numerous opportunities - from increasing productivity and reducing personnel costs to improving safety and stabilising quality. If you are considering this type of investment, start with a solid needs analysis and contact professionals who can help you select the optimal hardware and software solutions.

Want to learn more about our comprehensive welding robotics services or compare them to other automated processes? Visit the Michale Automation website and find out how you can develop your business with modern technology. Invest in the solutions of the future that will translate into real benefits - both in product quality and financial performance.

FAQ

How long does it take to implement robotic welding in a company?
The implementation time depends on the complexity of the processes and the integration needed with the existing line. It can be a few weeks for simpler jobs, or even several months for very complex projects and multiple test stages.

Is welding robotisation only suitable for large-scale plants?
Nowadays, the costs of such solutions are decreasing while their flexibility is increasing. As a result, even small and medium-sized companies are increasingly opting for welding robots to increase competitiveness, repeatability and production quality.

What are the key benefits of automating welding processes?
Above all, higher process efficiency and repeatability, lower risk of errors, improved worker safety and the ability to adapt quickly to changes in orders and production.

What if there are faults or the robot programme needs to be modified?
It is useful to have service support and access to a team of specialists. Often, suppliers such as Michale Automatics offer assistance with upgrades, service and maintenance, as well as training to enable quick troubleshooting.