Advanced Welding Systems

Delivering quality at a lower cost

The Advanced Welding System

An advanced robotic welding system lowers costs and improves quality, regardless of order size. It even improves safety and helps engineers create more innovative product designs.

Robotic welding isn’t just for resistance welds, although that makes a great application. A robot makes more consistent MIG and TIG welds than a human welder ever could. Neither is it just for high-volume manufacturers. Running medium- and low-quantity orders through a robotic welding system often yields an improved payback than extended runs. Even one-off welding jobs can be done economically by robot.

In an advanced welding system, a robot carries the torch while the parts being welded are clamped in place. Often they are mounted on a motorized positioner that improves access by providing additional motion axes. Larger, more complex parts might benefit from mounting the robot on a robot transport unit (RTU). When cycle times are short, a second robot can perform part handling or some of the welding.

With a pendant controller, the robot can be taught new motion paths on the plant floor, but many users prefer the flexibility of offline programming. Sophisticated software models the welding system and imports CAD part files, letting the programmer evaluate alternative paths and cycle times. This way, the robot keeps earning while the next job is developed.

No Minimum Order Size

Robots are flexible machines that can be easily reprogrammed and need minimal hard tooling. That means, there's little setup, making them practical for low-volume orders. Robotic welding even saves money on complex one-off assemblies, where the programming effort is repaid in faster welding and less risk of scrap. With fewer parts needed for setup, there’s more capacity for production.

Benefits

A robot moves faster and more consistently than a human welder. It gets into hard-to-reach places, never tires and never makes mistakes. Together, these mean an advanced welding system:

  • Produces more pieces per hour and per week than a human welder can.
  • Increases yields by avoiding mistakes. This eliminates scrap and sacrificial or test pieces while saving money and lowering costs — especially on complex, high-value jobs.
  • Improves schedule adherence, as no shortages mean every order ships complete and on time.
  • Lowers per-piece consumption of consumables like gas and wire because it moves faster while depositing only the minimum amount of metal needed.
  • Increases confidence in weld quality, possibly allowing less downstream inspection.
  • Enables designs requiring welds that a human welder cannot make because of restricted access or orientation (which gives engineering freedom to create more innovative products).
  • Improves safety by reducing human exposure to fumes, weld splatter and flash. (Reduced need for personal protective equipment is another cost saving!)

The Advanced Welding Solutions Company

Implementing welding robotics successfully demands extensive automation experience and a deep understanding of welding processes. Acieta has a long track record in welding automation, and expertise in building complete systems incorporating swing boom positioners, tilt/rotate tables and headstock/tailstock units. Partnering with FANUC, one of world’s leading robotics manufacturers, gives Acieta access to a huge family of advanced robots. With machines able to reach more than 2 meters (6.56 feet) and carry over 1,000 kilograms (2,204.62 pounds), there are advanced welding solutions to suit every manufacturer — large or small.

To discuss known automation opportunities or discover new ones:

DISPELLING ROBOTIC MYTHS

Myth:
Robots steal American jobs.
Truth:
Automation is necessary to bring part cost down so American products are competitive with the rest of the world. When our products are competitive, manufacturing stays here and companies hire more people in better occupations. By keeping manufacturing here, higher skilled, higher paid jobs are required to operate, program and maintain these systems.