Are robots taking over the welding industry?
This is a question many shop owners ask when the conversation turns to automation. Robotic welding machines can deliver consistently identical welds without variations from one to the next. So, many believe that automation will make human welders obsolete.
This couldn’t be further from the truth.
Robotic welding changes how work gets done, but it doesn’t eliminate the need for skilled welders.
Shops still rely on people who understand welding, can set up the system, and make adjustments when something goes wrong in the process.
This article takes a deep dive into robotic welding, its place in the production process, the operations it performs, and the areas that still require human oversight.
What Is Robotic Welding?
Robotic welding utilizes a programmed system to produce Welds along predetermined paths. The parameters that define how and where a robot creates a weld include movement, speed, or welding settings.
Once the robotic welding machine receives these instructions, it can generate identical welds on multiple pieces of material by processing them the same way each time.
To achieve this, parts must be securely held in place using fixtures, and the weld path needs to be programmed for the specifics of that job. Once set, the system runs that weld consistently.
Therefore, because robotic welding has a fixed, programmed process, it’s capable of producing consistent and repeatable results.
What Work Does Robotic Welding Handle Well?
Robotic welding is most efficient in applications where the parts repeat themselves and the process remains constant.
If the task involves making the same welds on a large number of parts, then consistency prevails.
Continuous processes such as MIG welding are popular among robotic operations due to their ability to provide continuous welds. On the other hand, spot welding works well for repeated connection points in sheet metal assemblies.
One of the reasons behind the rise in robotic welding technology is a projected labor gap. According to the American Welding Society, there will be a shortage of more than 300,000 welders in the country by 2029.
Robotic welding can help companies manage this shortage.
After a robotic welding system is programmed, the machine will consistently follow the same path each time. Consistent operating paths will minimize variation in the output and enable predictable production.
To sum up, robotic welding machines excel at repeatable, high-output tasks, which can help shops manage growing labor gaps.
Where Do Human Welders Still Play a Key Role?
The human factor is crucial in metal fabrication, particularly if the nature of work varies across jobs. Custom products, small production runs, and intricate assemblies need adaptations that can’t be pre-programmed.
One such example is TIG welding. This type of welding often relies on welder expertise, particularly when using thin metals or performing intricate work. In any automation setting, there has to be an expert who understands how the weld should look and perform.
Furthermore, welders play a critical role in troubleshooting and making adjustments if things change during the manufacturing process.
Therefore, human welders add value to production through their ability to adapt, use judgment, and actively solve problems, which keeps operations running smoothly.
How Do Robotic Welding Jobs Differ from Traditional Welding Roles?
Robotic welding is a job that requires welding knowledge, although the emphasis is now placed more on setup and system management. No more holding the torch. Instead, the operator programs the robot’s path, sets up fixtures, and oversees the result.
They make sure everything is correctly aligned, all machine settings are correct, and all welds are consistent. Should anything be even slightly off, the operator will have to adjust.
To sum it up, robotic welding jobs demand both welding and programming skills.
Does Robotic Welding Reduce the Need for Skilled Workers?
Robotic welding has significantly altered the way companies use labor, but it hasn’t eliminated the need for skilled workers.
If anything, it adds to the demand for people who are knowledgeable about welding and system setup.
Robots do only what they are programmed to do, so if a robot is programmed incorrectly, it will continue to repeat that same mistake. As a result, there’s still an ongoing need for skilled welders and technicians to oversee the process from start to finish.
Overall, robotic welding alters the demands of certain skills but still requires knowledgeable workers.
When Should a Shop Consider Robotic Welding?
When shops have repeat parts and steady production volume, they’re generally looking for automated processes like robotic welding. The reason for this is that they are able to produce the same weld repeatedly, which helps create consistency.
Robotic welding would also be a good option if your shop is looking to increase production volumes while reducing variability in the manufacturing process. This would allow you to maintain quality across larger volume production runs.
Or if your shop has varying workloads, you can also take advantage of robotic welding services, which will allow you to automate your welding operations without the need to invest in your own equipment.
Robotic welding is a good option for shops when repeat work and production volume support a consistent process.
How Do Robotic Welding Services Support Shops?
Companies can now outsource their automated welding projects to experienced providers. These providers handle setting up and programming all necessary equipment and production using established systems.
This can be beneficial if you don’t run consistent volume or if you want to try out automation before purchasing your own equipment.
It can also help you better manage spikes in production without having to overextend your own internal resources.
Robotic welding services provide companies with flexible access to automated welding processes.
Robotic welding isn’t putting humans out of business
It’s just doing things differently, with new roles in the process.
While robots perform the exact same “repeatable” jobs, workers are involved in preparing, fine-tuning, and performing those functions that require judgment and expertise.
As part of today’s manufacturing process, these two elements play an equally important role in helping factories operate at the highest possible levels of efficiency.
So, robots facilitate the process, and people keep everything on track.
Are you interested in learning more about how robotic welding fits into your operations? If so, reach out to Fluid Power Support. You’ll talk to people who understand fabrication and will guide you through all necessary steps.
