Welding processes in modern manufacturing - how to integrate welding robots into an existing line?

Estimated reading time: 9 minutes

TL;DR

• Robotisation of welding is becoming crucial to remain competitive in the market.
• It improves the repeatability and quality of welds while increasing production efficiency.
• Integrating a welding robot requires process analysis, selection of appropriate technologies and operator training.
• Modern robots can use vision systems to correct trajectories in flight.
• The return on investment (ROI) in welding robotisation can be achieved in as little as a dozen months.

Table of contents

• Introduction
• The importance of welding processes in modern industry
• Key benefits of automating welding processes
• Integration of a welding robot into an existing line - stages and challenges
• Welding robot technologies - what is worth knowing?
• Example of implementation process - case study
• Costs and cost-effectiveness - how to assess return on investment?
• How to start robotising welding in practice?
• Welding robotics and Michale Automation's offering
• Practical conclusions - what is worth remembering?
• Summary
• FAQ

Introduction

Welding processes are one of the key elements in modern metal production and beyond. Many companies that have hitherto relied on classic manual welding techniques are now looking at implementing automation in this area to meet the growing demands of the market. In an era of limited availability of skilled welders, diverse materials and pressure to maintain top quality, robotisation of welding processes is becoming not so much a luxury as a necessity. This is why the topic of integrating robots into an existing production line is so important - it allows you to remain competitive while paving the way for further growth of your business.

In this article, we explain the most important aspects of welding processes in modern production, how welding robots are integrated into available systems and what to look for when planning such a project. We also provide practical tips for companies considering automation in the welding area, and hint at the real benefits that can be expected.

The importance of welding processes in modern industry

Welding processes are a cornerstone in many sectors of the economy: from the automotive industry to the aerospace industry, to smaller factories producing steel structures or other metal components. As technology develops, so do expectations regarding weld quality, durability, repeatability or speed.

As welding often combines a wide variety of materials and thicknesses, it requires a great deal of knowledge and careful control of parameters. In this area, the decisive factors are:

• Selection of the right technique (e.g. MIG/MAG, TIG, laser)
• Precision of manufacture (ensuring the correct geometry and stability of the weld)
• Consistent high quality (e.g. no porosity, no repeatability)
• Adequate productivity (timeliness, elimination of production bottlenecks)

Without the use of modern methods, including robotisation, it would be increasingly difficult to meet these requirements. Hence the growing interest in integrating welding robots into existing lines and the need for expertise in this area.

Key benefits of automating welding processes

The implementation of welding robots is much more than just a trend. For many companies, it is a viable answer to challenges such as staff shortages, high production costs or the need to scale quickly.

Repeatability and quality of welds

The most obvious benefit of automated welding processes is repeatability. The robot can reproduce identical movements and parameters regardless of the number of repetitions. This means that every weld - if the programme is set up correctly - has the same high quality. With manual methods, even the most experienced welder can find it difficult to maintain consistent parameters with a large number of workpieces.

Increased productivity and cost optimisation

The robot can work almost continuously, around the clock. The problem of fatigue or the need to take a break is eliminated. As a result, the production cycle can be significantly shortened, which has a direct impact on greater plant productivity. In addition, with an efficiently configured system, energy efficiency increases, which reduces costs and increases profit margins.

Improving occupational safety

Welding involves high temperatures, the risk of burns and the inhalation of harmful gases. The use of robots relieves people of direct involvement in these dangerous stages. Welders can supervise the systems and working 'under the control' of a robot becomes less risky.

Integration of a welding robot into an existing line - stages and challenges

Implementing welding robots into a plant that already has some manufacturing infrastructure in place requires going through several key stages.

Analysis and selection of individual elements

The first step is to carefully analyse the entire process: from the material preparation stage, through the welding itself, to the acceptance and inspection of the workpieces. At this point, it is worth asking yourself the questions:

• Is the existing welding station suitable for easy robotisation, or will a major overhaul or replacement of equipment be required?
• What types of welds are to be made and is robotisation to cover all types of welding processes or just a selection?
• How the communication between the robot and the rest of the line (e.g. workpiece handling systems, MES or ERP)?

In order to optimally select the parameters and functions of the robot, it is necessary to determine the specific requirements in terms of weld type, speed and automation level.

2. technology selection and layout planning

After the initial analysis, it is time to choose the right model of robot, welding accessory, power source and possible welding sensors, cameras or 3D scanners. Many times it is best to speak to an experienced integrator who will assess the compatibility of the various components with the type of product.

The layout of the position is also planned at this stage, taking into account:

• Space for robot and workpiece feeders
• Optimum welding path
• Welding fume extraction system
• Operator protection (safety curtains, fencing)

The well-thought-out layout minimises the risk of collisions and ensures maximum smoothness.

3 Integration, training and trial tests

Implementing a welding robot means not only physically assembling and configuring the machine, but also integrating it into a production management system (e.g. MES or ERP) and the development of safety procedures. In order for the whole team to be able to make full use of the new tool, training of operators and process engineers is essential. Employees need to learn the basics of programming the robot, correcting welding parameters, maintenance and quick troubleshooting.

After implementation, production trials and weld quality checks are carried out to verify that all assumptions (cycle time, quality, productivity) have been achieved.

Welding robot technologies - what is worth knowing?

Different robotic welding methods

Although the most popular automation technologies are MIG/MAG and TIG, laser or hybrid welding - combining the advantages of an electric arc and a laser beam - is growing in importance in many industries. There are also robots adapted for spot welding, particularly useful in the automotive sector.

In laser welding, for example, the key is the high concentration of energy in a small area, which minimises distortion and speeds up the process. It is also high precision - ideal for applications with tight tolerances.

Automatic calibration and vision systems

Modern welding robots are increasingly equipped with vision sensors or adaptive systems that continuously monitor the position and quality of the weld. This enables the robot to correct its trajectory on the fly, eliminating deviations caused by inaccurate workpiece placement in the fixture.

Although the implementation of such solutions increases the integration time, in the long run it reduces the number of defects and increases the stability of quality.

Robot selection - key parameters

• Lifting capacity and reach - adapted to the size and weight of the component to be welded.
• Positioning accuracy - crucial for high quality requirements.
• Ease of programming and integration - it is worth checking that the robot's software interface is user-friendly for the personnel who will operate it.
• Matching the welding power source - different welding processes require different sources, e.g. MIG/MAG, TIG, etc.

Michale Automatyka works with, among others, robot manufacturer SIASUN. It offers models suitable for a variety of working environments, which can be adapted to specific needs. For example, you can find more information about your chosen model here:

• SIASUN Robot SR25A-12.2.-01

Example of implementation process - case study

Imagine a medium-sized company producing steel structural components for agricultural machinery. Until now, most of the welding was done manually. Due to increasing customer demand, the company decided to automate a key step.

Audit and needs analysis

The production director, together with the engineering team, commissioned an analysis of all the welded parts in the company. Those with the most repeatability and generating the most quality problems were identified.

Design and selection of equipment

Based on the data carried out, it was clear that a six-axis robot with a MIG/MAG chuck would be most beneficial. A position rotator was also planned to allow welding from several sides with minimal human intervention.

Integration and programming

Once the robot and equipment were delivered, integration into the existing production line began. One of the most important stages was the assembly of the rotary table and the engineering team learning the basics of programming in the robot software.

Result

According to calculations and tests, the robotised line has increased productivity by 35% and eliminated most of the errors associated with incorrect welding parameters. In addition, the number of complaints dropped. Manually welded workpieces often required corrections, while the robot maintained stable quality throughout the series.

Costs and cost-effectiveness - how to assess return on investment?

Robotisation has its budget requirements: purchase of the robot, control system, additional welding equipment. Then there are the costs of integration, layout and subsequent maintenance. It is therefore crucial to estimate the return on investment (ROI).

Factors influencing ROI

• Reduced labour costs: the robot can work non-stop and fewer people are needed to operate it.
• Reducing scrap: stable quality means less waste and complaints.
• Increased productivity: production speeds up, which often goes hand in hand with more orders from customers.
• Lower rework costs: precision welding reduces the need for rework.
• Stability of quality: allows new markets to be tapped and offerings to be developed without worrying about performance.

Michale Automatics provides a practical online tool to pre-estimate the profitability of an investment: ROI calculator.
The data entered into the calculator will make it easier to prepare a business plan and determine when the investment will pay off.

How to start robotising welding in practice?

1. set objectives and scope

Define whether you want to automate the entire line or only selected stages - such as welding one type of workpiece. This will allow you to focus on your specific technology and equipment requirements.

Choose reliable partners

Choosing an experienced integrator, such as Michale Automation, avoids many mistakes. A company with experience in building machines and production lines can fit robots into your existing infrastructure with your individual needs in mind. You can read more about the services offered here: Robotisation and integration in practice.

3. Ensure training and safety

Remember to properly train operators and engineers so that they are not afraid of the technology, but are able to extract the full potential from it. And don't forget the health and safety regulations and standards for robotic welding workstations.

4. Gradually develop capacities

Once you have successfully implemented one robot, you can increase the level of automation or add more robots over time. Often, in companies with a multi-shift model, one welding robot becomes the key to handling an increasing volume of orders.

Welding robotics and Michale Automation's offering

Michale Automation has specialised in building machines and production lines for years. Our company is a team of engineers and specialists who will help implement even the most advanced welding robots within your line. Therefore, in our catalogue you can find:

• Complex welding systems (e.g. robotised welding stations)
• Solutions for integration into vision, ERP/MES systems
• Assistance in selecting the right welding robot or cobot, depending on the requirements and dimensions of production
• Official distribution of SIASUN robots, ensuring access to the latest models and service support

Practical conclusions - what is worth remembering?

• Clearly define the area you want to automate - consider the types of workpieces, the scale of production and the quality targets.
• Select the welding technology (MIG, MAG, TIG, laser, etc.) and robot for your specific needs. Pay attention to the parameters of reach, lifting capacity and accuracy.
• Plan integration with your existing production management system, including communication with ERP or MES.
• Operator training is key - even the best robot won't work if staff don't know how to operate it properly.
• The cost of robotisation should be considered in the context of ROI - with increased productivity, reduced errors and less downtime, the investment can pay for itself in as little as a dozen months.

Summary

Automation of welding processes is the future of modern manufacturing. In an era of high quality requirements, pressure for efficiency and cost reduction, welding robots are becoming a key component of competitive companies. However, integration into existing lines requires careful preparation: from needs analysis, to the selection of the right equipment, to training and implementation tests.

With these solutions, companies not only increase quality and reduce manufacturing times, but also improve work organisation and safety. If you are considering robotic welding, be sure to check out the options available and talk to the experts. This will help you to avoid unnecessary costs while taking full advantage of the potential that modern technology brings.

It is worth looking at ready-made, proven solutions - you can find them in the Michale Automation portfolio. In our experience, even small companies are able to record significant profits if they opt for welding automation. So don't hesitate to explore your options, because robotisation is becoming standard in more and more industries, and the first companies are already gaining a competitive advantage by responding quickly to market changes.

If you would like to know more details about turnkey robotic welding process workstations, check out our solutions and robot range: Welding robotics - Michale Automation's offer.

You are also welcome to speak to our specialists, who will help you choose the optimum technical parameters for your process and guide you through each stage of implementation.

Thank you for reading the article:

• Are you interested in the topic of combining welding systems with ERP/MES software? Then be sure to visit Robotisation and systems integration
• Want to see a sample model of a welding robot? Check out SIASUN Robot SR25A-12.2.-01
• Wondering when your investment in a robot will pay you back? Try ROI calculator

Michale Automatika - official distributor of SIASUN robots, specialising in the construction of machines and production lines, industrial automation and the implementation of robotic workstations for welding processes and more. Our experience confirms that well-planned integration provides a company with a clear advantage - both in terms of product quality, costs and production time.

We encourage you to subscribe to our newsletter and share the article with those who may find the knowledge of robotisation and welding processes useful. We also look forward to your comments - we'd love to hear additional questions and stories from your production facilities that have opted for robotic workstations.

FAQ

How long does it take to implement automation in a company?
The implementation time depends on the complexity of the processes and available resources. It can range from a few weeks for simple solutions to several months for extensive projects and large integrations.

Does automation mean redundancies?
Usually no. Automation allows employees to focus on more creative and strategic tasks, while freeing them from monotonous tasks. Many companies use this to retrain and develop their team professionally.

Does robotisation only pay off for large companies?
Today, advances in technology are leading more and more small and medium-sized companies to turn to robotisation. Costs are coming down and flexible solutions can deliver a favourable return on investment even for smaller operations.