Robotic welding station - how to integrate it effectively into an existing production line

Estimated reading time: approx. 10 minutes

TL;DR

• Robotised welding provides higher productivity and repeatability in production.
• Analysis of existing processes and thoughtful integration of equipment into the production line is key.
• Investment costs can be recouped in as little as 1.5-2 years with appropriate optimisation.
• Safety and regular maintenance are the cornerstones of effective robot operation.
• Proper staff training allows the full potential of automation to be realised.

Table of contents

Introduction
Why consider a robotic welding station
Key steps in integrating a welding robot into the production line
How to adapt a robotic welding station to your company's specific needs
Safety and reliability - what to bear in mind
Most common errors in the integration of robotic large-scale solutions
Service, maintenance and further development
Summary - step-by-step integration
FAQ

Introduction

The robotised welding station is an increasingly common choice for companies that want to increase the productivity and quality of their production processes. In an era of ever-increasing market demands and limited availability of skilled welding personnel, automation is becoming a natural direction for many companies. However, it is not just about reducing production times. Robotised welding shops ensure repeatability and precision of operations, often impossible to achieve by humans.

Integrating a robot into a complex, existing production line can be a challenge. In this article, you will learn what to pay special attention to when planning the implementation, what benefits you can expect and how to ensure that the whole process runs smoothly and in a well thought-out manner. You will also learn practical tips for maintaining and servicing your robotic workstation. With this knowledge, you will increase the chances of successfully integrating a modern solution into your production line, which will translate into a faster return on investment.

Why consider a robotic welding station

A robotic welding station is an investment that can significantly speed up production and help maintain the highest quality standards. In the manufacturing industry, especially in the metalworking segment, it is difficult to maintain a stable level of quality with high volumes and limited human resources. A robot relieves workers of the most repetitive tasks and favours minimising the risk of human error.

Greater welding precision
The robot can be programmed to repeat the same welding cycle flawlessly - regardless of the number of parts realised. This ensures that weld quality remains consistent and the number of corrections is reduced.

Cost optimisation
Although the introduction of a robotic welding station means an initial expense (e.g. the purchase of a robotic arm, the relevant fixtures and control system), in the long term it saves significantly on labour and waste costs.

Improving safety
In some welding processes, the operator is exposed to harmful substances, high temperatures or intense arc radiation. Robotic workstations relieve people of dangerous and monotonous tasks, thus reducing the risk of accidents.

Michale Automatika, as an official distributor of SIASUN robots, specialises in the implementation of various types of robotic workstations, including welding. Although the initial costs of installing a robot can be high, the return on investment (ROI) is often already achieved within 1.5-2 years. If you would like to see sample calculations, use the
Check out the return on investment calculator for welding robotisation.

Key steps in integrating a welding robot into the production line

Integrating a robotic welding station into an existing production line requires careful planning and a lot of analysis. The whole process can be divided into three main stages.

Process analysis and pre-planning

The first step is to identify where in your production line welding is the bottleneck and where the biggest quality problems occur. Worthwhile:

• Make a list of all products and details that need to be welded.
• Analyse what the current cycle times are and what the expected capacity is.
• Assess the degree of repeatability and difficulty of the required weld (e.g. long welds, complex shapes).

At this stage, it is important to anticipate whether the new robot requires any changes to the line layout, retrofitting (e.g. rotary tables) or vision systems. Michale Automatics helps in this phase to make a technical assessment and carry out the first cost calculations.

Design and selection of equipment

The next step is to select a suitable welding robot with accessories.

• Choice of robotic arm
  The robot must have sufficient reach to handle all the components to be welded. Depending on the needs and nature of the work, these can be 4-, 6- or even 7-axis models. SIASUN robots, valued in the industry for their favourable cost-performance ratio, are an example of versatile equipment.
• Welding current source
  A good quality welding machine, the right filler metal and the right shielding gas are essential. It is sometimes necessary to use specialised equipment for MIG/MAG, TIG or arc welding methods.
• Software and control
  The robot must interface with the existing control infrastructure in the plant. It is worth noting the ability to integrate with MES/ERP systems to keep track of operating parameters and performance.
• Consideration of safety standards
  Compliance with relevant standards (such as ISO 10218-1 or EN ISO 12100) is a must to ensure the safety of operators and occupants in the vicinity of the robotised workstation.

Testing, training and optimisation

Before the robot is permanently installed in the production line, bench tests are carried out. Under simulation conditions, welding speed, precision and repeatability, among other things, are checked. Cosmetic adjustments to the software are often made at this stage.

When the workstation is working as intended, it is worthwhile to provide training for the operator. Robotisation means new procedures and sometimes a basic knowledge of offline programming is required. If there will be several similar robots in the company, common practices and documentation can be developed for internal use.

How to adapt a robotic welding station to your company's specific needs

Measures needed from a cost and ROI perspective

One of the key challenges is to understand that the profitability of an implementation depends on more than just the purchase price of the robot. Relevant factors are:

• Line adaptation costs.
• Modernisation of control systems.
• Implementation of additional sensors (e.g. for position detection of components).
• Scope of service support.

If you have any doubts as to whether robotic welding in your company will pay off, read the
our welding robotisation offer - you will find information on return on investment, example hardware configurations and possible material savings.

Technological and training challenges

The implementation of robotic workstations entails expanding the workforce with robot-related competences. It is not just about the basics of programming. The need often arises:

• Training in safe material handling and equipment maintenance.
• Familiarise yourself with automatic weld quality control methods.
• Integration with other equipment handling semi-finished products (e.g. conveyors, rotary tables).

In our experience, the optimisation of welding processes can yield up to 30-40% productivity gains within the first year after robot implementation. The prerequisite, however, is a properly trained team and ongoing technical support.

Safety and reliability - what to bear in mind

In the context of robotic welding, safety is not only a legal obligation, but also a factor in the comfort and motivation of workers.

• Enclosing the robot and welding area
  Eliminating the risk of an operator accidentally coming into contact with a robotic arm or an electric arc is essential. Specialised safety curtains and cages are often used.
• Safety sensor system
  It is important to implement emergency stop procedures (so-called E-stop). Many modern robots have built-in sensors to detect collisions and malfunctions.
• Technical inspections and maintenance
  Regular periodic inspections are recommended, e.g. every 3 or 6 months, to assess the condition of the main components of the robot and welder. Early detection of faults minimises the risk of prolonged downtime.

Safety issues are regulated by a number of standards (including EN ISO 12100). Remember that meeting them requires both the adaptation of the physical site and the creation of appropriate documentation, such as operating instructions and emergency procedures.

Most common errors in the integration of robotic large-scale solutions

• Insufficient verification of hall space
  There are times when a robot is able to carry out planned operations, but there is not enough space for operators to pass through safely or store semi-finished products.
• Choosing the power of the welding machine too hastily
  If you are welding sheets of different thicknesses, it is worth considering versatile solutions that allow you to switch seamlessly between different welding modes.
• No consultation with an experienced integrator
  Decisions made solely on price can lead to equipment mismatches. As a result, upgrades have to be carried out, further extending the payback time.
• Neglecting the role of employees
  A robotic welding station is a tool. Without a team that can operate it effectively, the machine will not become a source of real profit.

Service, maintenance and further development

Once integration is complete, it is important not to forget to keep the system in high working order. Regular maintenance work includes topping up lubricants in the robot joints, inspecting the welding torch and checking the quality of cables and wires. Any minor faults with the welding torch or robot are worth fixing at an early stage before a more serious breakdown occurs.

If you do not have sufficient staff resources for service or maintenance, support is provided by Michale Automation. To maintain the continuity of your processes, you can call on the help of a specialised department:
Service and maintenance of posts.

In many companies, the implementation of robotic welding is the first step towards further automation:

• Line extensions with additional robots (e.g. for packaging or palletising).
• Adaptation of the software to new product types.
• Vision system applications for even higher precision.

Summary - step-by-step integration

Integrating a robotic welding station into an existing production line does not have to be problematic, as long as you plan each step properly. Take care of:

• A thorough analysis of processes in welding.
• Well-thought-out robot selection in terms of reach, payload and welding method.
• Proper training of staff and provision of service support.
• Regular maintenance, including inspections and diagnosis of potential faults.

Additionally, it is worth checking whether your company can benefit from a grant or lease for robotisation. Modern companies are increasingly opting to lease robotic arms, so they can already reap the benefits of automation while paying off instalments.

See also how you can implement automation in other areas or learn more about our implementations:
Find out more about complex robotisation.

Practical conclusions
- Invest in planning - proper analysis of production processes and needs avoids many costly mistakes.
- Remember safety - invest in the right safety equipment and follow the standards to keep operators comfortable and minimise the risk of accidents.
- Training is key - even the best robot will not work effectively if the team is not well prepared to operate it.
- Work with a reliable integrator - industry experience will indicate how best to combine the robot with the company's electronics and already-in-use mechanisms.

We encourage:
- Contact Michale Automation for a personalised quote and consultation.
- Investigate whether your company meets the criteria to make the investment in a robot pay off in the short term.
- Carry out continuous optimisation, testing and improvements to the production line to fully exploit the potential of robotic welding.

Robotised welding stations are the future of many industries, and the increasing availability of technology is helping companies of all sizes to implement robots. The right preparation, the help of experienced specialists and ongoing employee training make the transition to automation smooth, efficient and cost-effective. If you want to take the first steps towards robotic welding, take a look at our current offering and see how we can tailor a solution to your needs:
Check out our welding robotisation services.

Thank you for reading. We hope that the information you have prepared will help you to effectively implement a robotic workstation into your production line and identify practical solutions to support the growth of your business. Share this article with your friends in the industry or contact us to get started!

FAQ

How long does it take to implement a robotic welding station?
The implementation time depends on the size of the plant, the complexity of the processes and the resources available. For simple solutions it can be a few weeks, while for more complex projects it will take several months.

Does robotisation of welding mean job cuts?
In most cases, robotisation does not involve mass redundancies. Automation allows workers to be reallocated to tasks that require more creativity and expertise, while improving safety and ergonomics.

Is robotic welding only for big companies?
No. As technology develops, automated welding stations are becoming more and more accessible, including for small and medium-sized companies. There are flexible solutions that can be adapted to different production levels and budgets.