ROBOTIC WELDING… from the Technician’s point of view

I recently sat down with Dwayne Smith, one of KC Robotics’ robotic engineers and a specialist is automated welding. I wanted to pick Dwayne’s brain about the benefits of robotic welding. Dwayne wanted to get back to work. “You don’t really want me to write something!” I assured him that I would do the writing. He humored me with answers to my obviously uninformed questions, but made it clear that he would rather be “back at the robot”.

This is what I got out of the conversation:

• Most of the welding applications set up by KC Robotics are MIG Welding.
• MIG stands for “Metal inert gas” (What does that mean?)
• In “MIG”, the weld is put down with a spool of solid-steel wire that is fed through the torch
• MIG is Dwayne’s preferred type of automated welding because it’s easier to automate with wire than it is with a stick and the “end of tip to torch is always consistent”.
• The key to quality automated welding is a good fixture and consistent input parts
• The benefits of automated welding are consistent welds, workplace economy, low overhead, and shorter cycle times. This means, in Dwayne’s words, “the end product is consistent, the robot saves bucks in labor costs, robots don’t complain, smoke cigarettes or file workers comp claims, and the factory is able to produce more product in a shorter period of time.”

I asked Dwayne why he likes welding jobs. He replied, “I don’t. Material handling is much easier.” So… why do you specialize is welding? I asked. In his typical economy of words, Dwayne answered, “I have a background in welding. It’s what I do.” With that, he excused himself so he could get back to work. “Marty (our customer) is probably looking for me,” he explained.

Before leaving the office, Dwayne plopped a book on my desk, saying, “I think the book can answer your questions better than me.”

Thanks, Dwayne. That’s what I wanted to do with my afternoon – read a welding textbook.

KC Robotics and Robotic Welding

KC Robotics specializes in system integration using new and used robots, individually designed end-of-arm tooling, project design and engineering, installation, and employee training. System Integration with robotic welding applications can be the most difficult of all applications. It requires more than one piece of equipment, including a robot, end-of-arm torch, wire feeder, welding gas, and a power supply. Because of the complexity of an automated welding system, it is important to partnership with a good integrator. The engineers and robotic programmers at KC Robotics can guide you and your employees through every aspect of setting up a robotic welding system. Contact KC Robotics for more information or a proposal. 513-860-4441 or info@kcrobotics.com

Most Popular Welding Robots sold at KC Robotics:

The most popular welding robots sold at KC Robotics are the ARCMATE 100 and 120 series and the FANUC S420if. The ARCMATE robots are perfect for manipulating the torch around small components. They are relatively small robots, fitting into tight manufacturing facilities. The ARCMATES are also fast robots which can increase the cycle time. The FANUC S420if has a longer reach, making it ideal for situations with large components.

Benefits of Robotic Welding Applications

The benefits of a robotic welding system completely outweigh the complexity of the set-up. Once the system is set up, the process requires little maintenance compared to manual welding. The benefits include:

• Quick return on investment
• Consistent welds
• Better Quality Control
• Less down time
• Increased cycle time
• Reduction in employee management expenses (insurance, workers comp, down time,etc.)
• Better working conditions for employees

MIG Advantages

• High productivity, because you don’t have to stop to change rods.
• Makes great-looking welds.
• Little cleanup.
• Can weld on stainless, mild steel, and aluminum.
• Can weld in all positions.

MIG Disadvantages

• Does not weld on paint, rust, or dirty surfaces.
• Not good for thick steel, because it doesn’t get the proper penetration.