The welding industry confronts a growing demand for professional welders, a scarcity of competent experts, and rising cost and quality expectations. However, integrating "collaborative robots," or cobots, into welding operations boosts efficiency and accuracy. Cobots can operate securely with people, have accessible programming interfaces, and are smaller than traditional industrial robots. Remember, welding with cobots means using them for arc, TIG, laser, MIG, ultrasonic, plasma, and spot welding for reliability while minimizing worker workload.
Advantages of Cobot Welding
Solving Labor Shortages: Addressing the skilled welder shortage, welding with cobots deploys the limited available workforce. Cobots use automated repetitive tasks to free up skilled welders for more complex jobs. It utilizes skilled labor to keep production levels.
Consistent Precision and Quality: Cobots may accomplish high repeat accuracy of +/- 0.03 mm for unvarying weld seams every time. It decreases errors and the need for rework with better-quality welds. The result is an unswervingly superior product.
Increased Productivity and Cost Reduction: Cobots operate without breaks for greater productivity. It helps cut production costs and realize a faster return on investment. Also, the preliminary cost might be recouped within a year due to increased efficiency.
Enhanced Safety: Cobots have built-in safety features that moderate workplace injuries. They operate with sensors that track motion, speed, and force for safe human-robot interaction. It promotes a safer working environment and disregards accidents.
Attracting Young Talent: Welding with cobots makes companies more desirable to young, tech-savvy experts. Cobots introduce unconventional technology into the workplace to attract the next generation of workers. It helps build a future-ready workforce.
Comparing Cobot Welding to Traditional Methods
Cobot welding is a flexible, cost-effective solution that bridges the gap between traditional industrial robots and manual welding. The reason is that it is easy to program and adaptive for low-volume, high-mix production runs. Cobots are intended for easy integration into current processes without considerable reconfiguration or safety barriers, unlike typical industrial robots, which are fast and productive but need trained programmers and expensive setup and operations expenses.
On the other hand, manual welding is customizable and adaptable. Still, human tiredness and variability cause irregular quality and greater error rates. Furthermore, cobots can work 24/7 and sustain production throughout high-demand times without raising personnel expenses.
Components of a Cobot Welding System
Key Components of a Cobot Welding System
Cobot welding systems need a robotic arm with a teach pendant, a welding power supply and equipment, and safety PPE. The robotic arm can precisely weld due to optimum load capacity and reach. Its repetition precision provides high-quality weld seams and saves rework. Programming and reprogramming are easy using the teach pendant's interface. Next, the welding power source powers reliable, high-quality welds. The welding torch, wire feeder, and shielding gas supply prevent material flow and contamination. Plus, safety PPE is essential. Ventilation systems, welding helmets, gloves, and cobot safety barriers limit fume, spark, and electrical dangers.
Layout Options for Cobot Welding
Three layout options improve efficiency in welding with cobots. These are easy integration on existing workbenches, efficient use between two stations, and highly automated welding cells. First, the cobot's small form allows it to be integrated into an existing workstation with few space changes. It suits little workshops. Second, place the cobot between two stations for optimal use. A cobot welds at one station while an operator prepares components at the other. Finally, highly automated welding cells are the most elegant. The enclosed systems with two stations and a linear axis enable effortless task changeover in these cells. Cobots' straightforward programming interfaces render them easy to use and provide high-quality output in exacerbated contexts.
Safety Considerations
Due to physical, electrical, and chemical risks, welding with cobots requires safety. Program cobots to avoid collisions and unwanted welding equipment contact. Cobots monitor motion, speed, and force for human operator safety. Electrical risks, including shock, fire, and explosion, need adequate grounding and insulation. Similarly, welding fumes contain metallic oxides, silicates, and fluorides, demanding ventilation and PPE to safeguard workers.
According to ISO-10218 and TS-15066, collaborative robot safety needs deep risk assessments. With these plans, cobots can function in human contexts without guards or obstacles. A thorough risk assessment documents hazards, calculates risk levels, and implements safety measures. E.g., assessing electrical shock risk may require building insulated barriers and performing periodic upkeep. Risk assessments should be updated to reflect workplace changes and safety concerns.
Cost and Return on Investment
Breakdown of Cobot Welding System Costs
Costs for welding with cobots include acquisition, programming, and maintenance. A cobot price may range from $8,000 to $100,000. Cost comprises a robotic arm, welding torch kit, power supply, and accessories. For programming, traditional robots need specialist coding skills. Yet, user-friendly interfaces in cobots cut training time, functioning delays, and programming expenses. Similarly, focusing on operator safety and upkeep, cobots have simpler systems that decrease maintenance costs. For instance, ongoing care includes checking and fixing welding torch components and wire feeders, which is cheaper than industrial robot maintenance.
Potential Returns on Investment
Cobot welding has several technical benefits that heighten ROI. Thanks to their continual operation, cobots boost productivity. For example, a cobot may weld 20-30 inches per minute while doubling throughput over human welding. ROI is further increased by cobots' accuracy, which lowers weld flaws. Skilled people do sophisticated projects, while cobots execute repetitive activities. Consequently, it minimizes manual welders and labor expenditures. Better workplace safety lessens injuries for lower insurance premiums and compensation claims.
If you also want to upgrade your workspace with cobot welding, let's join hands for a joint venture.
