Robotic Welding vs. Manual Welding

Robotic welding is another name for automated welding and involves one of two processes. The first option is fully automated welding, where machines take 100% control of the production process, from start to finish. On the other hand, in semi-automatic welding, an operator guides the loading and unloading of the material when the machine cycle ends.

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MANUAL WELDING

Manual welding is done by humans and not machines. This type of process continues to be widely used in certain market sectors, such as large-scale shipbuilding.

Advantages of Manual Welding

• Greater flexibility: manual welding workers do not need to be retrained each time they are given a different type of welding job.
• Easy to replacement: if one welder cannot weld on a given day, another welder can take over the project. This is in case you have a large team of welders. However, due to the lack of skilled labor this replacement is not that easy anymore.
• Recognition Ability: qualified welders can interpret the welding signals and sense if something is going wrong, such as if there is evidence of contaminated material or excess oxide, and this damages the weld.

Disadvantages of Manual Welding

• Risk: if an employee has an accident at work, he may be on sick leave for a few days or even months. A robot, in case something goes wrong, just needs to be fixed.
• Speed: robots are faster and more agile than humans during the complete welding process of a component and no interruptions in movement between welds.
• Efficiency: hardly two parts will be produced with the same level of precision.

AUTOMATIZE YOUR PRODUCTION NOW

Whether you’re considering welding aluminum or any other metal, robotic welding is increasingly the preferred option for many companies, for all the benefits it brings with it.

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Defined in the American National Standard: Standard Welding Terms and Definitions, AWS A3.0:2001:

1. Manual Welding ( MMA, TIG …)

Welding whereby the entire welding operation is performed and controlled by hand. Since the welder does all the work manually, it’s physically demanding and can lead to injuries.

In manual welding, as “welding with a torch, gun, or electrode holder is held and manipulated by hand,” the welder performs the welding function and maintains continuous control of the welding operations by hand.

2. Semi-Automatic Welding ( FCAW, MIG, MAG… )

In semiautomatic welding, defined as “manual welding with equipment that automatically controls one or more of the welding conditions,” the welder manipulates the welding gun to create the weld while the electrode is automatically fed to the arc.

3. Machine (Mechanized) Welding

Welding with equipment which needs operator manipulation or adjustment in response to changes in welding condition. The torch, gun, or electrode holder is held by a mechanical device and the mechanical device that holds the gun, torch or electrode can be a robot.

In mechanized welding, defined as “welding with equipment that requires manual adjustment of the equipment controls in response to visual observation of the welding, with a torch, gun, or electrode holder held by a mechanical device,” the welder’s intervention consists of adjusting the equipment controls in response to visual observation of operations.

4. Automated Welding ( SAW… )

Welding with equipment that needs only occasional or no observation of the weld, and no manual adjustment of equipment controls. For this type of welding, the welder’s activity is starting the machine and watching for defects or issues that need correction.

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In automated welding, defined as “welding with equipment that requires only occasional or no observation of the weld, and no manual adjustment of the equipment controls,” the welder’s involvement is limited to activating the machine to initiate the welding cycle and observing the weld on an intermittent basis, if at all.

5. Robotic Welding

Welding performed and controlled by robotic equipment which requires no involvement from the welder. The welder’s main function in robotic welding is to maintain quality control and fix any deviations or issues.

Robotic welding, defined as “welding that is performed and controlled by robotic equipment,” entails no involvement on the part of the welding operator in performing the weld, as the welding operations are carried out and controlled by welding robots.

What are the differences between mechanised, automated and robotic welding?

The definitions of each term according to the British Standard BS 499:Part 1: 1991 are as follows:

Mechanised welding – Welding in which the welding parameters are controlled mechanically or electronically and may be manually varied during welding to maintain the required welding position.

Automatic welding – Welding in which all of the welding parameters are controlled. Manual adjustments may be made between welding operations but not during welding.

Robotic welding – Automatic welding using a robot that can be pre-programmed to different welding paths and fabrication geometries.

Successful application of mechanised/automated systems can offer a number of advantages. These include increased productivity, consistent weld quality, predictable welding production rates, reduced variable welding costs and lower part costs. Limitations include higher capital investment than for manual welding equipment, a need for more accurate part location and orientation, and more sophisticated arc movement and control devices. As such, production requirements must be large enough to justify the costs of equipment and installation, the maintenance of equipment and the training of operators/programmers for automated/robot equipment.

Reference document:

+ TWI

+ AWS A3.0

+ BS 499

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