One of the least understood and complex production processes is welding. While many companies emphasize and spend a lot of money on assembly automation, automatic welding such as the WeldSaver is often ignore. However, a reasonable number of manufacturers are now embracing water-saver automation technologies to ensure increased product quality, profitability, and productivity. Welding automata come in two basic categories: fully automatic and semiautomatic.
Fully Automated Welding
Fully automatic welding involves a custom WeldSaver machine or a series of machines that can carry out the entire welding process without a human operator. For water saver welding machines to do that, they will require a special program. The series of machines can automatically load, workpiece, position the torch and part, perform the welding process, check the quality of the joint, and upload the finished product. If necessary, “part in place” will have to be included to check the quality of the final product. The application will determine whether there is any need for a human operator.
Semiautomatic welding requires a human operator to manually load the parts into the welding fixture. This has to be done base on the preset parameters of the entire welding process. The welding process, the stillness of the parts, and the motion of the torch are kept in place by the weld controller. The completed assembly is then remove once the welding process ends and starts all over again.
You need to understand that not all welding applications will work well with the WeldSaver machine. If a weld’s function or quality is critical, then automated welding will be highly beneficial. If you require identical parts or repeatability in your welds, fully automatic welding is need. Some of the applications that require automatic fully automatic welding include the manufacturing of metal bellows, transducers, light bulb elements, relay enclosures, thermos flasks, batteries, solenoids, capacitor cans, medical components, transformer cores, nuclear devices, valve elements, airbag components, fuel filters, and pipe fittings. Companies that manufacture limited amounts of items that need critical or accurate welds may not require fully automatic welding because it is quite expensive. In this case, semiautomatic welding will work well to produce substantial ROI.
Benefits of Automated Welding Systems
There are four main benefits that automated welding offers. They include increase output, improved weld quality, decreased variable labor costs, and decreased scrap. The quality of the weld is determine by repeatability and integrity. Electronic weld process controllers ensure that integrity is met. For high-quality weld or workpieces, combining part motions with an electronic recall of welding parameters with mechanized torches is necessary. This will give you a high quality that can’t be achieve manually.
Moreover, if there are any defects, they can be detect easily since a weld is only make once. Most manual welders will only smooth over a mistake using a torch, leading to flawed welds. Additional quality control is make possible with leak testing and vision systems.
Drawbacks of Automatic Welding Systems
Although automatic welding or WeldSaver offers many benefits depending on the application, there are several drawbacks that you can encounter using automatic welding machines. The constraints can be controll, but they should be consider before purchasing and installing automated, semi-automated, or manual welding machines. Compare to manual welding machines, the initial investment required in an automatic welding system is very high. Therefore, this has to be considere before purchasing and installing automatic welding systems. You have to ensure that the investment will allow the company to meet its bottom line and provide sufficient ROI.
Automation of machinery has playe a great role in ensuring items’ quality and repeatability are achieve. In automatic welding, numerous parts and welds are produce quickly, which makes it a perfect choice for manufacturers who produce larger quantities of items.