Believe it or not, welding automation has been in use since 1962. From automotive production lines to shipbuilding, robotic arms, and the software that runs them, the technology has played an important role in producing increasingly complex parts in shorter periods of time. However, robotic cells are not just for the big guys.
When done right, such automation improves productivity, part quality, and ROI. But before adding a robotic cell, companies need to carefully weigh three important factors: infrastructure, workforce, and technology.
A robotic cell’s footprint is three dimensional, including both the equipment and its movement. The cell might look small when idle, but its range of motion can more than double its actual footprint. Other space considerations include leaving room for cranes and conveyors, loading and unloading, and whether employees can safely get around the cell to other parts of the facility. At Pemamek, we partner with customers to determine which components of our modular welding systems will work best for their operations. With more than 50 years of consulting and innovation under our belt, this is one of the most important pieces of advice Pemamek gives to potential customers.
Implementing automation doesn’t mean hiring more people. But it does mean that a company’s workforce needs to be ready to learn and do new things, such as robotic operation and control software. In other words, welders need to become cell operators. For welding companies and their employees, this is a win-win situation. Cell operators are able to produce more quality parts per shift, and they acquire new skills that can help extend their careers. There are also safety benefits as cell operators are removed from the arc and molten metal, and they no longer need to contort themselves to complete a complicated part.
Digital readiness can’t be overlooked. Paper drawings and blueprints need to be converted into digital files that can be used to produce and test weld paths.
This can be a significant investment with purchasing software and systems, hiring and/or training at least one programmer, and ensuring the entire workforce is well versed in the system.
It’s important to weigh each consideration against the benefits of an automated cell. Is there a good location to place the cell? What safety concerns need to be addressed? Will an investment in new technology pay off? How soon? Are employees willing to add new skills to their knowledge base?
One robotic cell can do the work of three welders, enabling companies to ramp up productivity despite the industry’s lack of qualified welders. The right welding system is easy to learn, program, and adjust as needed, allowing welders to accommodate different parts, or even different welds on the same part, with little or no stoppage.
Having an experienced welder at the helm of a robotic cell brings years of knowledge to the table. Servo-driven and servo-motorized workpiece positioning along with five- or six-axis robotic welders enable operators to position the piece to maintain consistent downwind position and weld pool. A weld control and corresponding software lets users program and simulate welds to pinpoint the most efficient toolpaths before work starts.
A properly programmed and managed robotic cell can constantly maintain part quality on even the most complicated parts down to the micron. And the creation of data files can be hard-wired into the production process, simplifying the quality assurance and documentation processes.
Putting a welder in charge of a properly outfitted cell with multiple robotic welders is an ROI booster. Running in multiple shifts pushes returns through the roof.
Conservatively speaking, investing in a robotic welding cell can pay for itself in six months or less for smaller systems, and a little more for large systems used in very complex projects such as offshore wind towers. Even then, the long-term savings in time, money, and resources are worth the investment.
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