Welding Automation: How Robotic Welding Works
How robotic welding works? This automation process uses industrial robots, welding equipment, positioners, fixtures, sensors and control systems to perform welding operations with greater consistency and repeatability. Robotic welding can automate repetitive welding tasks and help manufacturers improve production efficiency, weld consistency and process control.
This guide explains how robotic welding works, the main components of an automated welding system, common welding processes, and when welding automation may be suitable for a manufacturing application.
What Is Welding Automation?
Welding automation is the use of automated machinery and control systems to carry out welding operations with limited manual intervention. A robotic welding system typically combines an industrial robot with a welding power source, workholding, positioner, safety equipment and control systems.
The robot follows a programmed path while the welding equipment controls the welding process. Depending on the application, sensors, vision systems and additional automation equipment can also be used to monitor or control the process.
How Does Robotic Welding Work?
A robotic welding system is programmed to move the welding torch along a defined path while maintaining the required position, speed and welding parameters.
1. Component Positioning
The workpiece is positioned using fixtures, clamps or automated positioners to ensure that the component is presented consistently to the robot.
2. Robot Movement
The industrial robot moves the welding torch through the programmed welding path while maintaining the required orientation and reach.
3. Welding Process
The welding power source controls the welding parameters while the robot maintains the programmed movement and torch position.
4. Positioning
A positioner can rotate or reposition the component so that different welds can be completed efficiently.
5. Inspection
Depending on the application, sensors, cameras or other inspection equipment can be incorporated into the system.
6. Repeatable Production
Once validated, the programmed process can be repeated across compatible production components.
Components of a Robotic Welding System
A robotic welding system consists of considerably more than the robot arm itself. The complete system must be designed around the component, welding process, production requirements and safety requirements.
Industrial Welding Robot
The robot provides the controlled movement needed to guide the welding torch accurately along programmed welding paths.
Robot Controller
The controller manages robot movement, programmed paths, operating sequences and communication with other parts of the welding system.
Welding Power Source
The welding power source supplies and controls the electrical power and welding parameters required for the selected welding process.
Welding Torch & Torch Package
The torch delivers the welding process to the component. The torch package can include cables, hoses, torch mounting and other required connections.
Robot Positioner
A positioner rotates or repositions the workpiece to provide better access to weld locations and improve the efficiency of the welding process.
Fixtures & Workholding
Fixtures hold components securely and consistently in the correct position during automated welding.
Safety Fencing & Guarding
Safety systems help separate personnel from the robot's operating area and can include guarding, interlocks and emergency stop equipment.
PLC & Control Systems
PLCs and control systems coordinate the robot, welding equipment, positioners, sensors and other automation equipment within the cell.
Sensors & Monitoring Equipment
Sensors and monitoring systems can help detect component position, process conditions and other information required for automated welding.
Wire Feeding & Gas Systems
Wire feeders deliver welding wire while gas systems supply the shielding gas required for suitable welding processes.
Part Loading & Unloading Equipment
Automated loading and unloading equipment can transfer components into and out of the welding cell to support continuous or higher-volume production.
Welding Processes Used With Industrial Robots
Industrial robots can be used with several different welding processes. The appropriate process depends on the material, component design, weld requirements and production environment.
MIG and MAG Welding
MIG and MAG welding are widely used in automated welding applications because they can be suitable for repetitive production and a wide range of fabricated components.
TIG Welding
Robotic TIG welding can be used where controlled and precise welding is required, particularly for suitable materials and applications where weld quality and appearance are important.
Arc Welding
Robotic arc welding is commonly used for repetitive manufacturing applications where programmed torch movement can provide consistent weld paths.
Spot Welding
Robotic spot welding is frequently used in applications involving repeated weld locations, including suitable automotive and metal manufacturing processes.
Why Use Welding Automation?
Welding automation can provide advantages where production involves repetitive welding operations and consistent component presentation.
- Repeatable welding movements
- Consistent torch positioning
- Reduced repetitive manual operations
- Potentially higher production throughput
- Improved process consistency
- Better control of programmed welding parameters
- Ability to automate repetitive production tasks
- Integration with wider manufacturing automation
When Is Robotic Welding Suitable?
Robotic welding is generally most suitable where components can be presented consistently and the welding process involves sufficient repetition to justify automation.
Robotic welding may be suitable when you have:
- Repeated production of similar components
- Consistent component geometry
- High welding frequency
- Long or repetitive welds
- Stable production volumes
- Consistent fixtures and component positioning
- A requirement for repeatable welding paths
When May Robotic Welding Be Less Suitable?
Automation is not appropriate for every welding application. Very low production volumes, highly variable components or difficult-to-fixture parts may require a different approach.
A feasibility assessment can help determine whether robotic welding is technically and commercially suitable before investment in equipment.
A Welding Robot Is Only One Part of the Automation System
The industrial robot is only one component of a complete robotic welding solution. Successful automation depends on how the robot, welding equipment, positioner, fixtures, controls and safety systems work together.
For this reason, selecting a robot should normally be based on the complete application rather than robot specifications alone.
Looking to Buy a Welding Robot?
Robot Store supplies new and refurbished industrial welding robots and robotic welding systems for manufacturing applications.
Explore available welding robots, brands, applications and pricing information on our dedicated commercial welding robot page.
Buy Welding RobotsIs Your Process Suitable for Robotic Welding?
Before choosing a welding robot, it is important to consider the component dimensions, material, weld type, production volume, cycle time, welding process, fixture requirements and available floor space.
Robot Store can help assess your application and identify the equipment and automation approach required for your process.
Welding Automation FAQs
What is robotic welding?
Robotic welding uses an industrial robot to control the movement of a welding torch through a programmed welding path. The robot works together with welding equipment, fixtures, positioners, controls and safety systems.
How does a robotic welding system work?
A robotic welding system positions the workpiece, moves the welding torch through a programmed path and controls the welding process according to predefined parameters.
What welding processes can robots perform?
Depending on the equipment and application, industrial robots can be used for MIG, MAG, TIG, arc and spot welding, among other automated welding processes.
Is robotic welding suitable for small manufacturers?
It can be, particularly where there is sufficient repetition or production volume to justify automation. A feasibility and commercial assessment can help determine whether robotic welding is suitable for a specific application.
How much does welding automation cost?
The cost depends on the robot, welding equipment, positioner, fixtures, safety systems, controls, programming, installation and commissioning requirements. For current welding robot pricing and system options, see our welding robots page.
Ready to Explore Robotic Welding?
Whether you are investigating welding automation or already have a defined production requirement, Robot Store can help you assess the application and identify suitable robotic welding equipment.
Welding Automation Experts
Explore our welding automation consultation services. We specialize in refurbishing and selling cost-effective industrial robots from leading brands. Enjoy a complimentary consultation, dependable after-sales support, and easy access to spare parts to meet your business needs. Learn more: Will robots replace operators?
Technical, Operational, and Human Aspects of Welding Automation
Welding robots work best when you choose the right robot, design proper fixtures, set the right process parameters, and integrate sensors effectively. Don’t overlook the importance of training workers, performing maintenance, and ensuring safe, adaptable, and quality production.
Operational Considerations
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Cycle Time & Productivity
- Optimize robot path and speed for quality and throughput.
- Reduce downtime with automated wire cutting and cleaning.
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Part Quality & Repeatability
- Maintain tolerances within robot limits.
- Standardize components to reduce variability.
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Maintenance & Reliability
- Establish preventive maintenance for robots and tools.
- Regularly replace consumables (tips, nozzles).
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Safety
- Design cells with guards and safety measures.
- Ensure proper fume extraction and ventilation.
- Train operators for safe maintenance and setup.
Human & Organizational Considerations
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Skilled Workforce
- Training in robot programming and troubleshooting.
- Integrating manual welders for complex tasks.
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Production Flexibility
- Designing for quick reprogramming.
- Using modular setups for product lines.
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Quality Assurance
- Implementing in-process inspection.
- Conducting post-weld non-destructive testing.
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Cost & ROI
- Evaluating investment vs. savings.
- Considering energy efficiency and downtime.
Technical Considerations
Welding Process & Parameters
- Select a suitable welding process (MIG/MAG, TIG, etc.) based on materials.
- Correctly adjust voltage, current, and travel speed for quality welds.
Robot Type & Payload
- Choose a robot with suitable reach and payload for the task.
- Consider wrist torque limits for welding tools.
Workpiece Positioning & Fixturing
- Design effective fixtures to hold parts accurately.
Use positioners for complex welds and better access.
Torch & Tooling Setup
- Ensure proper torch alignment and calibration.
- Organise cables to minimize tangling.
- Use anti-spatter systems and cleaning stations.
Seam Tracking & Sensors
- Incorporate vision systems to maintain weld quality.
- Implement adaptive control for dimensional changes.
