Benefits of Welding Automation

       

Improved Weld Quality

Weld quality depends primarily on two factors - weld integration and repetition. Weld integration is a programmable weld process controller that uses blueprint or CAD designs for reference. As long as the process and the weldments remain constant, the weld output will be the same. For example, welding positioners aid in the positioning of the weldments correctly and ergonomically within the right distance of the welding area. Every time a mechanized positioner will repeat the same process of bringing the weldments to the same place in the same alignment for the right amount of exposure to the welding torch, ensuring right weld. This will improve the weld quality and finish.

Decreased Variable Labor Costs

A semi-automatic system has capacity to produce output, double that of a skilled labour. A fully automatic system can produce eight times the output of a skilled labor. When a skilled labor does not report to work, the producer's eight hours of production time are lost. By investing in automation and hiring a general worker to handle or supervise the process, a producer can decrease the variable labor cost.

Decreased Scrap

Automating torch movement or other parts, and their placements reduce human error. In an automated set up, a weld will take place only when pre-conditions are met. This is unlike with manual processes, where numbers of scraps increase with human fatigue.

Use of advanced welding manipulators such as computerized plasma cutters can help reduce scrap through precise cutting.

Increased Output

In an automated welding process, there are many constant factors involved, which decrease the setup time for a welding activity. As the welding speed of a product is dependent on setup time, the machine can work at higher weld speeds, which in turn increases the output.