Welding is a difficult and hazardous process that is crucial in the production of many products. Many companies still use brute force and manual welding as methods of joining parts, where the alternative method utilizing robotic welding systems to automate welding processes can provide a number of advantages for companies of all sizes. From improved consistency and quality to less waste and lower costs, this blog outlines the advantages of implementing robotic welding systems.
Combat the Shortage of Skilled Welders
It is becoming harder and harder for many companies to fill their open welding positions. The American Welding Society projects that by 2023, there will be a shortage of over 375,000 welders in the U.S. which is a major problem for many companies. For companies who are able to find welders to hire, it is difficult to train and retain them. Robotic welding systems help overcome these issues and provide an immediate solution.
Consistent, High-Quality Welds
Manual welding takes a great deal of skill and concentration to consistently produce quality welds. Even the best welders make mistakes from time to time. Robotic welding systems offer an extremely high degree of repeatability and precision. Over and over, they can place a high-quality weld in the same spot without losing concentration or making a wrong movement.
Low-Quality Human Weld Example
Robotic Weld Example
Higher Productivity & Throughput
Robotic welding systems can work much faster than humans. They also don’t need to take breaks, get lunch, go home, or sleep. If necessary, robots can tirelessly work 24/7 at a rapid pace while continuously turning out high-quality work. There’s also no more time spent grinding or re-working sub-par welds which helps contribute to the substantial increase in outputs that robotic welding systems can provide.
Increase in Plant Safety
Welding is a tough and hazardous occupation. Welding workers are exposed to a number of risks, including toxic gases and fumes, flash burns, electric shocks, and more. Robotic welding systems can endure these hazards and protect human workers from being exposed to them. Additionally, this can prevent or considerably reduce accident and insurance related costs for the company.
In analyzing the investment for a robotic cell, it is important to consider the Total Cost of Ownership over the long-term (7+ years) as robotic systems last a long time and the cost-savings can be significant. Considering the most significant savings come from manual welding direct labor, this strengthens the return on investment for robotic systems. Additionally, robotic welders conserve materials such as weld wire and only use the necessary amount. The cost of these materials adds up quickly over time and using them more economically can provide a great deal of cost-savings. Lastly, as we mentioned, robotic welders can prevent (or considerably reduce the potential for) significant accident and insurance related costs for manufacturing companies.
With robotic welding systems, everything is controlled and regulated which means they only use the necessary amount of energy and power. Additionally, with the consistency and quality that robotic welding systems provide, the amount of scrap is drastically reduced.
Learn More about Robotic Welding Systems
Interested in learning more about robotic welding systems or wondering if one is the right fit for you? Mechatronic Solutions is a leading distributor of Yaskawa Motoman robotic welding systems and is here to answer any questions you might have. Just give us a call at (763) 447-3407 or fill in the Contact Us form to speak with one of our engineers!