Welding Automation for Productivity and Profitability
Welding automation involves the use of machines to increase speed and precision while producing high quality welds. These systems are easy to integrate in a production environment and cut the risk of errors and inconsistent welds, leading to higher productivity. This approach allows companies to become more environmentally friendly and help end the need to send jobs overseas. For companies on a tighter budget, there is the option to rent or lease several types of welding related equipment.
When Quality Welds are Critical
Welding is one of the most complex manufacturing processes. Both manual and automated welding has their distinct advantages. For many assemblies, manual fusing may still be the ideal alternative. However, welding automation is a recommended process where quality of the joint is critical. It is also a viable option when soldering done repeatedly on same parts.
Semi-Automatic vs. Fully Automatic
There are two categories of welding automation namely, semi-automatic and fully automatic. In semiautomatic soldering, parts loading into the soldering fixture, is a manual process, while a weld controller keeps motion of torch and stillness of the parts at preset parameters. Once the fuse is complete the operator removes the assembly and repeats the process. In fully automatic soldering, a customized machine or series of machines loads the work-piece, places the part or torch in place and completes the weld. The machine also monitors quality of the weld and unloads the welded product. A series of quality checks can also be designed into the machine. Companies that assemble products in limited quantities but must correct welds can benefit from a semi-automatic system.
The Benefits of Welding Automation
Welding automation offers four distinct advantages which include quality, increased productivity, decreased labor costs, and less wastage. Quality achieved by combining mechanized torch and part motions with electronic recall of parameters. By eliminating the human reason from the welding process both semi-automatic and fully automatic systems help increase output. With high speeds and minimal setup time, automated soldering systems can easily outpace manual soldering.
Welding automation includes several systems that include positioners, manipulators, turning rolls, bed rollers, cutting machines, wire feeders, and remote monitoring, to name a few. A soldering positioner is a convenient aide to increase productivity and quality. With the help of a positioner setting up work-pieces to the best possible positions can increase productivity by as much as 70 percent. It also allows for ergonomic working comfort, which is essential for welders that otherwise may work in stressful environments.
Welding is an integral part of almost every industry. With the increasing demand for high quality welding and advancements in technology, welding automation is the ideal way to increase your ROI.