Robotic welding - how do you integrate a welding robot into an existing production line?

Estimated reading time: 8 minutes

TL;DR

• Welding robots are growing in popularity due to high productivity and accuracy
• A needs analysis and audit of the existing production line is key
• Correct configuration and simulations before implementation are important
• Initial costs can be high, but the return on investment is measurable
• A welding robot is often the first step towards full automation

Table of contents

• Why is robotic welding gaining in popularity?
• Planning and preparation for the implementation of a welding robot
• Integration of the welding robot into the production line - step by step
• Examples of solutions at Michale Automatics
• Challenges and ways to solve them in the implementation of robotic welding
• Potential for further expansion and cooperation with other systems
• Summary - key findings and recommendations
• FAQ

Introduction

Robotic welding is increasingly appearing in manufacturing companies looking to streamline processes and increase competitiveness in the market. According to data from the International Federation of Robotics (IFR), the number of industrial robots worldwide is growing at a rate of several per cent each year, and a significant proportion of these are welding robots. In this article, we will explain how to approach the integration of a welding robot into an existing production line in order to gain maximum benefits at the lowest possible cost. After reading, you will learn why robotic welding is the future in industries relying on metal joining processes, how to plan a step-by-step implementation and when the investment in a welding robot pays off.

Why is robotic welding gaining in popularity?

Welding is one of the most important processes in many industrial sectors, including metal, automotive, aerospace and construction. With the increasing demand for fast and repeatable processes, manual welding has started to lag behind the needs of the market. A solution has therefore emerged in the form of robotic welding systems that allow for increased productivity and precision, as well as improved workplace safety.

Reasons for the growing interest in welding robotisation

• Rising labour costs - robotic workstations can operate 24/7 without interruption, reducing operating costs in the long term.
• Staff shortages and the need for fast order processing - welding robots are able to take over monotonous and high-precision processes.
• Improving quality - The robot is able to produce identical welding stitches in hundreds or thousands of copies, while reducing errors and rejects.
• Improved worker safety - automation eliminates the need for direct human intervention in a process exposed to high temperatures, radiation or welding fume emissions.

Trends in welding robotics

The IFR report shows that welding robots are a significant part of new installations in the industry. Alongside this, better vision systems and adaptive sensors are emerging, which allow robots to weld parts of varying shape or size. Integrations with IoT systems are also gaining in popularity, allowing real-time monitoring of welding parameters and quicker rectification of potential technical problems.

Planning and preparation for the implementation of a welding robot

The proper integration of a welding robot does not start with the purchase of the equipment, but with a thorough analysis of the needs and capabilities of the production facility. Many companies fail to realise the potential offered by robotic welding due to shortcomings in planning or a too superficial approach to technological requirements.

Stage 1 - Analysis of needs and processes

At the outset, it is crucial to understand what elements in the company will be welded:

• What size are these details?
• What material were the intermediates made of? (Steel, aluminium, plastic?)
• What welding methods are currently used? (MIG/MAG, TIG, laser?)
• How much partisanship is there in production and do elements change frequently?

It must also be determined whether the robot will only handle one type of product or whether the line is mixed. In welding automation, additional vision systems are often used so that the robot can 'detect' the position and geometry of the workpiece. It is on this type of detail that the subsequent selection of the appropriate welding robot depends.

Stage 2 - Audit of existing production line

Once the production assumptions are defined, an audit of the existing infrastructure is carried out. The key questions are:

• Are there already welding stations in the line that just need to be modified?
• What type of workpiece transport was used? Can it be integrated into the robot?
• Is there sufficient space to insert a robotic cell?
• What does the welding fume supply and extraction system look like?

At this stage, it is also important to determine whether the introduction of a welding robot will require modifications to the PLC control of the entire line, as well as to discuss weld doping needs (e.g. welding sensors, vision systems). W Michale Automation We help to analyse all the key elements so that implementation takes place smoothly and with the specifics of the production in mind.

Stage 3 - Selecting the right robot and tooling

Choosing the robot itself is only part of the success. Selection is also important:

• A welding source adapted to the method (e.g. MIG/MAG with pulse, high-frequency TIG).
• A welding fixture that is precisely matched to the type of workpiece.
• A rotary table or positioner if it is necessary to rotate workpieces during welding.
• Security systems (light curtains, fences, security locks).

For example, plants welding large steel structures use robots with higher payloads and a wide arm reach, while a medium-sized welding robot with high speed and a specialised fixture will work better for precision welding of aluminium components in the automotive industry.

Integration of the welding robot into the production line - step by step

Once the analysis and hardware selection phase is over, it is time for the practical integration of the robot. This usually takes place in several stages, which we discuss below.

Step 1 - Design and simulations

Before physically placing the robot at the line, a concept and computer simulations are necessary. A well-planned project shows:

• Where exactly should I position the robot so that the reach of its arm covers all the planned welding points?
• What is the optimum movement trajectory so that the robot works as quickly as possible and does not collide with other line elements?
• How to deploy security systems and sensors?

Such simulations make it possible to verify initial assumptions and identify potential collisions or process bottlenecks.

Step 2 - Installation and configuration of the robot

Once the technical design has been approved, it is time for assembly. The foundation or support structure to which the robot will be attached is installed. Next, the welding source, cables, fixture and possible vision systems are installed. It is important that the power supply and earthing of the entire set-up are properly provided.
The next step is to configure the software and communicate with the main line controller. If your company has ERP/MES systems in place, you may need to integrate production data to record welding parameters in a database.

Step 3 - Tests and optimisation of the welding trajectory

Once the assembly is complete, a series of tests are carried out, during which the robot welds the first test pieces. Engineers check:

• The quality of the weld and whether the parameters meet the expected standards.
• Process stability (whether there are any disturbances, e.g. insufficient fume extraction).
• Communication with the production line (compatibility of start/stop signals, safety loops).

At this stage, adjustments are made to the welding programmes, tuning speeds and source parameters. Only when the process proves stable and repeatable can the robotised workstation be considered ready for full production.

Examples of solutions at Michale Automatics

As Michale Automation, we deal with complex implementations of machines and production lines, as well as the integration of robotic workstations in companies from various industries. Thanks to our experience and official distribution of SIASUN-branded robots, we provide state-of-the-art tools tailored to the company's specific requirements.

- If you are interested in robotised welding as a key automation in your company.
- Do you want to know a specific model the SIASUN SR25A robot dedicated to welding processes?
- Considering whether such an investment is worthwhile? See the initial calculations in ROI calculator in welding robotisation.

In the process of implementing robotic workstations, every element - from robot selection to integration to operator training - is taken care of by us. We support both large plants with a high degree of automation, as well as medium-sized or small companies taking their first steps in robotisation.

Challenges and ways to solve them in the implementation of robotic welding

While the benefits of implementing welding robots are great, it is important to be aware of the challenges that may arise during integration.

Initial costs

A welding robot, together with the entire infrastructure (welding source, vision system, positioner, safety system), can be a considerable investment. The solution may be to obtain grants to support innovation, use technology leasing or implement in phases (e.g. one robot first and after a test period further extend the line).

Retraining the team and changing the working model

Workers who previously welded parts themselves have to learn a new way of working - how to operate and program a robot. Hands-on training is required and sometimes support during the start of series production. In the long term, this transformation has a positive effect, as staff develop valuable competences in robotics and automation.

Potential line downtime

If a robot is coupled to an entire production line, any fault can bring the entire line to a halt. This can be helped by:

• Predictive maintenance systems that continuously check the robot's operating parameters and report possible abnormalities.
• Regular service and maintenance as recommended by the robot manufacturer.
• Quick access to spare parts and technical support.

W Michale Automation Among other things, we offer service and maintenance services to minimise the risk of failure.

Potential for further expansion and cooperation with other systems

Robotised welding does not mean the end of automation in a company. Once implemented, the robot can be expanded in the future with additional functions such as:

• Remote monitoring of welding parameters and sending alerts in case of deviations.
• Integration with vision systems for real-time recognition of workpiece alignment.
• Work with AGVs (Autonomous Guided Vehicles) to transport details between sites.
• Expansion to include automated parts storage or palletising systems, also robotised.

In addition, welding robots are increasingly being linked to ERP/MES systems so that all production data - from planning to execution to quality control - is in one place. This makes it possible to keep track of welding productivity, the current load on the line and breakdowns and interruptions.

Summary - key findings and recommendations

- Robotic welding is the answer to rising labour costs, pressure for high quality and a shortage of skilled welders.

- In order to successfully integrate a robot into an existing production line, it is necessary to perform a process audit, select the appropriate equipment and tooling and prepare the team for the new way of working.

- Integration should be preceded by simulations and tests to rule out design errors and optimise welding trajectories.

- Although the initial costs can be significant, over time the investment pays off in the form of consistent, repeatable weld quality and a reduction in errors and downtime.

- The welding robot can be the start of further automation, with possible interfacing with vision systems, CNC machines or full integration with ERP/MES.

Robotic welding, especially in the context of integration into an existing production line, is increasingly seen as a strategic step towards the industry of the future. It makes it possible to achieve reproducible welds of the highest quality, reduce operating costs and limit the risk of accidents. However, implementation requires careful preparation - from process audits to simulations to employee training. Properly executed integration is a guarantee of a stable, efficient process and the possibility of further expansion with further automation modules.

If your company is considering automation and wants to bet on robotic welding, it is a good idea to start by consulting an experienced team of engineers. At Michale Automation, we help you at every stage - from the initial idea, to the selection of the robot, to the final integration into the production line.

We encourage:
- Contact us directly to discuss the specific requirements of your production line.
- Read additional materials, case studies and other articles on our blog.
- Testing ROI calculatorto assess the profitability of investing in a welding robot for your company.

With robotic welding, your company can step up to a higher level of productivity and product quality. It's a good time to make a decision that, over the coming years, could decide to strengthen your market position and better prepare you for the challenges of modern industry.

FAQ

How long does it take to implement a welding robot?
The implementation time depends on the size of the project and the complexity of the processes. In simple applications it can be a few weeks, and in complex lines even a few months.

Is a welding robot cost-effective for small production?
Much depends on the specifics of the products and the frequency of product changes. Robotisation can be beneficial even in medium-sized and small companies if repeatability and stable quality are required.

Which welding methods can be robotised?
MIG/MAG and TIG robots are most commonly used, but robotised laser or plasma welding stations are also available - it all depends on the needs and type of material.

Do employees need to have programming knowledge?
Operating modern welding robots mainly requires training in the user interface and safety procedures. More advanced programming is carried out by qualified engineers or technicians.