Welding Digest

If you look closely at the ever-evolving landscape of manufacturing and, more specifically, at the intricate world of cobot welding, it becomes clear that a few key elements are essential for achieving success with cobots. Here are some tips for unlocking the full potential of collaborative welding robotics.

Increase Welding Efficiency with Cobots

Welders sometimes have a misguided fear that cobots will replace their roles in manufacturing. In reality, these machines often make their jobs easier. Cobots serve as a tool to streamline large production runs and manage monotonous, repetitive tasks that are usually dreaded by welders. Cobots reduce the learning curve to welding, and I have witnessed individuals with limited to no prior welding experience produce high-quality products at an impressive throughput rate. Cobots can be the key to unlocking higher productivity, even with a depleting welding workforce. Finding expert welders is a tough process today, but introductory gas metal arc welding tutorials from YouTube can provide new operators with a solid foundation in welding principles for cobot welding — even if they have never picked up a torch.

One notable benefit of the increasing presence of cobots is their integration into educational settings at an early stage. This integration has enabled students to gain hands-on experience with robotics, equipping them with practical skills before they enter the workforce. Consequently, this trend has the potential to alleviate some of the challenges associated with finding skilled labor for programming industrial robots. With a growing number of individuals already familiar with cobot operations upon graduation, the transition into industrial settings becomes smoother, streamlining the recruitment process and addressing the demands of an ever-evolving industrial landscape.

The Vital Role of Fixtures in Collaborative Welding

The significance of fixturing in cobot welding cannot be overlooked. Fixtures play an important role in minimizing the errors associated with part loading into the welding cell, effectively preventing potentially costly collisions or the production of scrap parts. In any welding setup, fixtures act as the guiding hand, bringing precision and reliability to the process by ensuring that parts are consistently positioned for seamless welding. This reduces the risk of errors and promotes efficiency by minimizing setup time between cycles. In addition, using fixtures in cobot welding helps to address variations in part forming, pushing the parts together to compensate for forming inconsistencies. Ultimately, fixtures are the unsung heroes in cobot welding, streamlining operations and enhancing the overall quality and productivity of the welding process.

The effectiveness of fixtures is often related to their simplicity. Basic fixturing blocks, clamps, and clamping squares are readily available from local welding suppliers or online retailers and can significantly enhance the welding process. Alternatively, the use of sheet metal-designed fixtures and toggle clamps to construct custom fixtures has proven to be a game-changer for frequently produced parts. Welders often experience remarkable improvements in production efficiency by using fixtures since the fixtures reduce setup time and eliminate the need for program adjustments between parts.

Integrate Innovative Tab and Slot Designs

The incorporation of innovative tab and slot designs in part production significantly streamlines the manufacturing process, especially when coupled with effective fixturing. Redesigned components, resembling the popular interlocking mechanism of building blocks, now snap into place like puzzle pieces, simplifying the assembly of parts onto fixtures.

In the pursuit of precision and seamless assembly, TRUMPF Inc. uses a simple design practice when integrating tabs and slots into parts. The choice increases the slot size by 0.12 mm (0.0047 in.) all around and ensures the smooth insertion of tabs, compensating for any potential discrepancies in sheet thickness. To deal with overlapping outside edges, we reduce the tab length size to 80% of the material thickness. This intentional adjustment ensures that the welds on outer corners meld seamlessly, resulting in a refined and visually appealing finish free from unsightly protrusions or irregularities. By implementing these design considerations, you create an easier assembly for operators. Reducing the time between runs when loading fixtures results in more parts being welded daily.

Final Thoughts

Time and patience are the most effective teachers for acclimating operators to cobots. No two individuals share the same programming approach, and ultimately, the key to success in cobot welding is personalization. The unique qualities and preferences of each operator should guide the path toward mastering the art of cobot programming. Often, it is about emphasizing the importance of individuality in this dynamic field and finding what works best for each operator.

Opportunity abounds for ingenuity in fixturing, programming, and part production using cobots. The impact of having the right individual operating the robot cannot be overstated. It is remarkable how a compatible and skilled mind behind the machine can revolutionize the entire process. Finding the perfect match between human expertise and technological precision can ensure success and foster company growth. Time and again, it is the people and their skills and passion that ultimately drive the transformative power of cobot welding in the industrial landscape. 

TOMMY ZOLADZ (Tomasz.zoladz@trumpf.com) is advance technology welding engineer, TRUMPF Inc., Chicago, Ill.