Welding Automation Can Be Very Beneficial To Your Business-queer as folk

UnCategorized The automotive manufacturing industry has embraced welding automation in a big way for a long time. The abilities of robot welding has caused the number of units to grow to more 120,000 units as of 2005. Early growth in the numbers of robotic units was limited by the high equipment costs and somewhat limited application of automated welding to high production scenarios. Just before 2009 the growth in the number of automated welding units had attained 20% of the total of all industrial robot applications. The robotic welding unit that is a member of this population is made up of the manipulator and the controller, which tells the manipulator what to do. The welding automation unit can be based on a SCARA robot or it can be Cartesian. The design of the total unit is usually based on the way that the welding work station will be integrated with other work stations. Welding automation is a great improvement over the results that are attained by manual welding. The quality and consistency of automation far out paces what can be done by hand. The two main characteristics that define the quality of a weld are weld integrity and the repeatability of a weld. With an automated welding work station the integrity of the weld is produced through the electronic weld process controllers. Repeatability of high quality welds is a result of the .bination of trained torch and part movements and the recall of welding parameters from the controllers. These two factors simply cannot be consistently repeated in a manual welding process. As long as the welding automation work station can present the parts to be welded consistently in the range of tolerance that is required by the manufacturing process, the welds should always be the same quality. Human errors and inconsistencies are eliminated by the placement of parts by a robotic device. Manual welding often will yield a certain percentage of scrap, requiring rework or loss of materials. The human work in the welding operations is always impacted by fatigue and other inconsistencies that contribute to the need for closer quality control. The advent of automated welding in manufacturing cuts the costs of scrap and of close scrutiny by quality control. Welding automation increases the throughput of the welding work station. Having a robot do the welding increases the safety in the plant, while the cost of getting the job done is reduced significantly. After the installation of a welding work station a business can get a quick return on its investment. There are two types of welding work stations that can be added to the production line, semiautomatic and automatic. The semiautomatic work station has a human tender whose responsibility is to load the part that is to be welded into the fixture. The critical movement of the torch, consistent stillness of the part, and retrieval of weld parameters are performed by the controller. When the weld is .pleted the tender removes the .pleted part to start the process again. With the automatic welder performs all the tasks without the need of a tender. Both the semiautomatic and automatic welding work stations have cycle times that are not dependent on any human intervention, so the production line will run at a consistent speed. A .pany that is displacing several talented welders from the production line by installing welding automation work stations should allow for the retention of welding skills. It takes a training and practice to develop a high degree of skill in manual welding. It probably would be a good idea for some of that manual welding skill to be kept viable for possible use in the future. Also it is important for the .pany to do all required maintenance on the welding work station to keep it running at maximum pace. Historically, .panies would not want to be involved in trying to use welding automation work stations in their production lines because of a feeling that welding is too .plex to automate. All too many manufacturing operations would spend a great deal of money automating other parts of the production process. The welding would remain a manual process. As time has passed and a better understanding of the welding process has been gained, there have been more .panies realizing the benefits of automated welding. Cost can be a limiting factor for some manufacturers. To setup a semiautomatic welding work station it might cost as much as $30,000, while an automatic one might cost as much as $250,000. With this amount of variation the .pany should evaluate the return on investment that the appropriate device will give before choosing which one to employ. There is some lead time in bringing any new work station online. A manual welding work station can start working in a few hours, while a semiautomatic work station could be working in a couple of months. The automatic work station probably would take about 4 or 5 months to be operational. Not all production welds are great candidates for welding automation. Those that do have a high qualification are the ones that can be done repetitively, with the same weld being performed each time. Usually welds that have a high need for quality are good candidates for automation. Some products that are very good candidates for automated welding are batteries, fuel filters, solenoids, relay enclosures, capacitors, pipe fittings, and a lot of other products that are produced in high daily quantities. Manufacturing operations that produce in small batches would best be served by semiautomatic rather than automatic welding work stations. About the Author: 相关的主题文章: