Integrating welding robots into an existing production line - what you need to know about welding robotisation

Estimated reading time: approx. 10-12 minutes

TL;DR:

• Robotisation of welding helps to increase productivity, reduce costs and improve process precision.
• Implementing a robot requires careful planning, selection of the right equipment and integration with control systems.
• Adapting infrastructure, logistics and providing regular training for operators is key.
• The investment in welding robots often pays for itself in 1.5-2 years, which is attractive for companies of all sizes.
• Adequate management support, employee acceptance and concern for safety are the foundations of successful integration.

Table of contents

- Introduction
- Why is robotisation of welding becoming a necessity?
- Key steps in welding robot integration
- Elements for successful integration
- The most common problems and how to solve them
- Benefits of implementing robotised welding
- Case studies - success stories of small and medium-sized companies
- Robotisation of welding in the context of Michale Automation services
- Useful tips and good practices
- Related services and development prospects
- Practical conclusions / summary
- FAQ

Introduction

Robotisation of welding is one of the key developments in modern production. It is no longer only the large automotive corporations, but also smaller companies that are increasingly opting for automation and robotisation of processes. As a result, they are cutting costs, reducing lead times and increasing product quality. In this article, you will learn why the integration of welding robots into an existing production line is one of the most important steps towards modern, sustainable and efficient production today. We will outline specific benefits, challenges and good practices to help you make an informed decision about implementing welding robotics solutions in your company.

Why is robotisation of welding becoming a necessity?

Welding robotisation is not a fad, but a strategic response to the challenges of modern industry. Pressure to cut costs, a shortage of skilled staff or increasing quality requirements are leading more and more companies to look to automation as a way of staying competitive. In parallel, technology is advancing - robotic arms are now able to perform complex welding operations more precisely and safely, while adapting to dynamic changes in the production environment.

Increasing quality and performance requirements

In industries such as automotive, aerospace or white goods manufacturing, even a small deviation from the required standard can lead to serious problems - from complaints on a massive scale to end-user safety risks. Welding robotisation achieves excellent repeatability and reduces defects such as weld porosity, incorrect electrode angles or edge fouling. It is estimated that the implementation of a robotic welding station can reduce the number of defects created by up to 60-80% compared to manual work, resulting in both lower quality costs and higher customer satisfaction.

The challenge of a shortage of skilled labour

Due to an ageing workforce and the reorientation of younger generations to other professions, finding a competent welder may be more difficult than ever in many regions. Welding robots do not require regular breaks or social conditions and, thanks to modern programming features, can adapt to changing working conditions (e.g. different material or part geometry). As a result, automation reduces the risk of production downtime and frees workers from the most onerous tasks.

Key steps in welding robot integration

Integrating a welding robot into an existing production line requires precise planning and coordination, especially if the line was not previously designed for robotisation. The following are the most important steps to include in the project schedule.

Audit and analysis of current processes

The first step is a thorough review of existing production methods. It is worth identifying:

• Parts and assemblies requiring the greatest welding precision.
• Frequent recurring defects, e.g. cracks in welds or deformations.
• Downtime and moments when manual welders cannot keep up with the pace of the line.
• Potential logistical bottlenecks: whether the flow of material to the welding station is smooth and automated or needs to be rebuilt.

Such data will give a good estimate of the ROI of a welding robot implementation. At Michale Automatika, where we implement robotic workstations, we often additionally recommend short pilot tests or simulations, which reveal non-obvious problems and help to select the optimal configuration.

Choosing the right type of robot and welding technology

Not every production process requires the same type of equipment. Articulated robotic arms work well where high flexibility of movement in multiple axes is needed (e.g. welding parts with complex shapes). Cartesian and SCARA robots, on the other hand, are valued in applications with parallel linear movements or at very high welding speeds.

The choice of welding technology is related to the material and the level of precision required. MIG or TIG welding can be crucial depending on whether the production involves steel components, aluminium or structures made of specialised alloys. In practice:

• MIG (Metal Inert Gas) is suitable where speed is of the essence and for welding larger series of parts.
• TIG (Tungsten Inert Gas) is chosen for components requiring the highest purity and quality of welds, such as in the aerospace industry.

Integration of robots with accessories and control systems

Successfully linking a robot to an existing line also means ensuring software compatibility. If the company is using an ERP solution (e.g. for order and warehouse management) or MES (for real-time production monitoring), then integration with a welding robot will make it easier to track key metrics such as:

• Actual working time of the robot.
• Welding material requirements.
• The number of units produced over a specified period of time.

It is also worth making sure that the wire and shielding gas supply system can be synchronised with the robot's control interface. Modern sensors are capable of correcting the position of welds even in a fraction of a second, so as to maximally reduce defects resulting from small deviations in component alignment.

Testing, implementation and training of the team

Once the robot has been installed, it is time for trial tests. Make sure that:

• The robotic arm can move throughout its intended range without collision.
• The welding parameters (current, voltage, wire feed speed) are optimised for the material.
• Smoke extraction and ventilation at the welding station correspond to the higher health and safety requirements for continuous operation.

Training of operators and the maintenance team is extremely important to prevent errors due to improper operation or maintenance of equipment. At Michale Automation, we place a strong emphasis on the transfer of knowledge to the customer so that they can start fully automated production quickly and efficiently.

Elements for successful integration

Many entrepreneurs ask what ensures successful integration and what factors can hinder it. Among the key aspects we can mention:

Consistent management support and organisational culture

Implementing welding robotisation is not only about buying equipment, but also about changing certain working habits. If management does not provide adequate support and employees are sceptical or even fearful of redundancy, the project may encounter internal resistance. Therefore, it is extremely valuable:

• Clear communication of the actual objectives: reducing defects, increasing competitiveness and ensuring higher health and safety standards.
• Reallocating skilled staff to more advanced tasks, such as quality control or job programming, rather than eliminating full-time positions altogether.

Adaptation of infrastructure and logistics

Even the best welding robot will operate inefficiently if it is not provided with a smooth flow of material. The lines must be organised in such a way that the robot does not wait for parts and the operators can quickly make changes to the software or to the welding fixtures. In certain situations, the distance the raw material has to travel (e.g. from the sheet metal warehouse to the station) has to be taken into account.

Compatibility with security systems

Today's welding robots have advanced vision sensors or safety functions (e.g. emergency stop in the event of a collision), but the entire production line must be equipped with mechanisms to protect workers. From proper signage, safety curtains and scanners to appropriately configured work zones. This is especially true in applications where robot and human operate in close proximity.

The most common problems and how to solve them

Despite its many advantages, robotic welding brings with it some challenges. Here are some typical difficulties that may arise during integration:

Incorrect setting of welding parameters

The wrong current, the wrong type of gas or too high a wire leading speed can lead to poor quality welds. The solution is to carry out a detailed analysis and process trials. In doing so, it is worth using the expertise of engineers specialising in welding automation, such as the Michale Automation team.

Insufficient training of robot operators

In the case of new technologies, the proper training of employees responsible for programming and operating robotic workstations is often forgotten. This will translate into a higher risk of breakdowns, production errors and even stopping the entire line. The key here is a comprehensive training path that combines both theory (knowledge of software and health and safety standards) and practice (exercises on real components).

Inconsistent data flow in the ERP/MES system

A common challenge is the discrepancy between the information from the ERP system and what is actually happening on the shop floor. If the welding robot does not receive timely data about the next production order, downtime can result. Best practice is to closely integrate the new robot with the ERP/MES system - so that data on the status of the order, wire consumption and planned time for completion of the operation are updated in real time.

Benefits of implementing robotised welding

Wondering if the introduction of welding robots will really deliver tangible results? Here are the key benefits:

Improving productivity and quality

The robots can operate continuously around the clock, maintaining a consistently high quality of welds - it is estimated that non-conformance levels can drop by up to several tens of per cent. This has a direct impact on improving the company's profitability.

Reducing accidents and risks to workers

Welding tasks involve the emission of fumes and high arc temperatures. Welding robots take over the most dangerous stages of the process and effectively protect people from hazards, which in turn translates into a higher level of safety in the plant.

Cost reduction and rapid return on investment (ROI)

Modern solutions allow even small companies to streamline processes that previously required a lot of human labour. In the experience of Michale Automation, the time it takes for a return on investment in welding robotisation is not uncommon to be between 1.5 and 2 years. Want to estimate the benefits in your own company? Use
ROI calculator for welding robotisation.

Case studies - success stories of small and medium-sized companies

Until recently, robotised welding was sometimes associated only with large automotive concerns or the aerospace industry. However, more and more smaller companies are embracing this technology. An example of this is a small steel construction company that, after implementing a MIG welding robot, reduced the number of deficiencies by 40% and reduced material costs, as fewer welds required touch-ups and additional repair exercises.

In contrast, another company operating in the HVAC industry used collaborative arms (so-called cobots) to weld thin-walled pipes. Workers, who previously spent long hours in uncomfortable positions during precision welding, have moved to job programming and quality control. As a result, both productivity rates and crew satisfaction increased.

Robotisation of welding in the context of Michale Automation services

Michale Automation (also known as Michale Automation) specialises in machine and production line construction, industrial automation and the implementation of robotic workstations in various industries. As an official distributor of SIASUN solutions, we offer:

• Professional advice on the choice of technology and type of welding robot (MIG, TIG, spot welding).
• Comprehensive integration with existing line and ERP/MES systems.
• Customised projects tailored to the needs of small, medium and large enterprises.
• Servicing and maintenance of current positions to guarantee uninterrupted 24/7 operation.

We invite you to take a look at our offer on
robotisation of welding.

Useful tips and good practices

• Conduct constant monitoring of the welding parameters - any deviations are worth catching at an early stage.
• Opt for modularity - if you are considering future expansion of your line, choose solutions that facilitate integration with additional feeders.
• Plan preventive maintenance to avoid unexpected failures and long downtimes.
• Designate 'local experts' - trained people within your company who can respond quickly to modifications and failures of the robot.

Related services and development prospects

If you see that welding automation is producing tangible results, it is worth considering further areas for robotisation. Here are some examples:

Robotisation of packaging and stacking of components

Once the components have been welded together, they can be transported in an automated manner to packaging or palletising stations. For more details, see the offer for
robotisation of packaging.

Service and maintenance stands

Over time, each line requires inspection and possible replacement of components. To ensure the long life of the equipment and to avoid faults, it is worth reaching for a professional
service and maintenance of robot stations.

Practical conclusions / summary

- Robotisation of welding is a tool that makes it possible to significantly increase productivity and production quality, especially for large series or complex geometries.
- Integrating a robot into an existing line requires careful planning and needs analysis - fitting the equipment to the individual context is key.
- A well-thought-out implementation brings a return on investment in a relatively short time (1.5-2 years), making welding automation attractive even for smaller operators.
- Providing comprehensive support - from consultancy and design to staff training and ongoing service - is a guarantee of maximising benefits.
- It is worth considering long-term development plans and thinking about further robotisation of further stages, such as packaging, palletising or quality control.

The integration of welding robots into the existing production line is a milestone in the modernisation of the plant and the answer to the biggest pain points of traditional welding. Increased competitiveness, improved quality, reduced costs and increased employee safety are just some of the many benefits. If the topic has inspired you and you are wondering how to effectively implement welding robots in your company, we encourage you to read other industry articles and take expert advice. Let the road to a fully robotised, modern company become your next market advantage!

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 the right solutions can deliver a favourable return on investment even for smaller operations.