Study of Welding robots

P. V. Logics . January 31, 2023

 Welding robots are the most widely used for industrial automation. Nearly half of all industrial robots are deployed for robotic welding. Arc welding applications account for twenty percent of all robotic welding processes.

 The speed, accuracy, and repeatability of industrial robots makes them ideal for automating arc welding processes. Manufacturers gain the quality of an expert welder immediately with the implementation of an arc welding robot for a completely optimized welding system.

Welding robots are the most widely used for industrial automation. Nearly half of all industrial robots are deployed for robotic welding. Arc welding applications account for twenty percent of all robotic welding processes. The speed, accuracy, and repeatability of industrial robots makes them ideal for automating arc welding processes. Manufacturers gain the quality of an expert welder immediately with the implementation of an arc welding robot for a completely optimized welding system. Arc welding applications are typically automated with a six-axis industrial robot. The robot’s main purpose is to position the torch and workpiece while energy is supplied to the articulated robot from the power supply. Multi-purpose robots were typically used to automate arc welding processes, however, in recent years robotic manufacturers have developed robot models designed specifically for arc welding. Arc welding robots feature a slimmer profile and internalized cabling for more efficient welding. FANUC’s arc welding robots, the Arc Mate series, features the FANUC Arcmate 120ic. While Yaskawa Motoman’s arc welding robots come from several lines including the EA, MA, and VA series. The Motoman VA1400 features an additional 7th axis for increased flexibility and better torch access. In general, arc welding applications involve permanently joining metals together through the use of electricity. The electricity creates the electric arc needed to heat and melt metals. The following are the types of arc welding applications that can be automated with industrial robots: • GTAW – Gas tungsten arc welding is one of the most common robotic arc welding processes. Robotic GTAW is considered to be a precision welding method that is best for detailed welds and can only be used to weld thin metals. The Motoman MA1400 is ideal for GTAW automation, producing clean welds which is especially important for weld seems that will be visible. • GMAW – Gas metal arc welding is another popular arc welding process for robot automation. GMAW robots are often deployed when thick metals need to be joined together. The ABB 1600 can weld thick metals in a short amount of time with the GMAW method since a filler wire is melted between the metals to join them together, instead of melting the base metals themselves. • FCAW – Flux core arc welding is a versatile welding method. FCAW robots can weld both ferrous and non-ferrous metals using a tubular wire electrode. The advantage of robotic FCAW is that it can be used to weld dirty, rusty, or painted metals, saving time by not needing to clean the metal surface beforehand. • PAW – Plasma arc welding is another precision arc welding process for both thin and thick metal welding. PAW involves the use of plasma to join metals together at incredible speeds. Plasma arc welding robots can weld metals with a single pass of the torch, regardless of metal thickness. These robots can also be used for robotic plasma cutting applications with the same EOAT. • SAW – Submerged arc welding may be the least common robotic arc welding process, but it is the best for thick plate welding as well as longer welds. SAW is still relatively new to welding automation, with it only getting its start with industrial robots in the last ten years. Continuous arc welding? Submerged Arc Welding (SAW) A frequently-used process with a continuously-fed consumable electrode and a blanket of fusible flux which becomes conductive when molten, providing a current path between the part and the electrode The four main types of welding are: Gas Metal Arc Welding (GMAW/MIG), Gas Tungsten Arc Welding (GTAW/TIG), Shielded Metal Arc Welding (SMAW), and Flux Cored Arc Welding (FCAW). Spot welding Spot welding is a type of electric resistance welding used to weld various sheet metal products, through a process in which contacting metal surface points are joined by the heat obtained from resistance to electric current. Wikipedi Use for steel and stainless steel only. For more heat (amperage output), use shorter tongs. For units without a heat control, tong length can be used for a control. For instance, for thin metals Advantages of Spot Welding The process can be easily automated through the use of welding robots. Multiple metal sheets can be joined at the same time. No filler material is consumed, unlike some other methods (MIG welding). Cost-effective and economical as it doesn’t use inert gases or filler metals.23-May-2022 Spot welding (also known as resistance spot welding) is a resistance welding process. This welding process is used primarily for welding two or more metal sheets together by applying pressure and heat from an electric current to the weld area. 3 stages of spot welding? Spot Welding Electrodes seated in a weld head are brought to the surface of the parts to be joined and force (pressure) is applied. Current is applied through the electrodes to the workpiece to melt the material. Current is removed but electrodes remain in place at force to allow the material to cool and solidify.

Arc welding applications are typically automated with a six-axis industrial robot. The robot’s main purpose is to position the torch and workpiece while energy is supplied to the articulated robot from the power supply. Multi-purpose robots were typically used to automate arc welding processes, however, in recent years robotic manufacturers have developed robot models designed specifically for arc welding. Arc welding robots feature a slimmer profile and internalized cabling for more efficient welding. FANUC’s arc welding robots, the Arc Mate series, features the FANUC Arcmate 120ic. While Yaskawa Motoman’s arc welding robots come from several lines including the EA, MA, and VA series. The Motoman VA1400 features an additional 7th axis for increased flexibility and better torch access.

In general, arc welding applications involve permanently joining metals together through the use of electricity. The electricity creates the electric arc needed to heat and melt metals. The following are the types of arc welding applications that can be automated with industrial robots:

  • • GTAW – Gas tungsten arc welding is one of the most common robotic arc welding processes. Robotic GTAW is considered to be a precision welding method that is best for detailed welds and can only be used to weld thin metals. The Motoman MA1400 is ideal for GTAW automation, producing clean welds which is especially important for weld seems that will be visible.
  • • GMAW – Gas metal arc welding is another popular arc welding process for robot automation. GMAW robots are often deployed when thick metals need to be joined together. The ABB 1600 can weld thick metals in a short amount of time with the GMAW method since a filler wire is melted between the metals to join them together, instead of melting the base metals themselves.
  • • FCAW – Flux core arc welding is a versatile welding method. FCAW robots can weld both ferrous and non-ferrous metals using a tubular wire electrode. The advantage of robotic FCAW is that it can be used to weld dirty, rusty, or painted metals, saving time by not needing to clean the metal surface beforehand.
  • • PAW – Plasma arc welding is another precision arc welding process for both thin and thick metal welding. PAW involves the use of plasma to join metals together at incredible speeds. Plasma arc welding robots can weld metals with a single pass of the torch, regardless of metal thickness. These robots can also be used for robotic plasma cutting applications with the same EOAT.
  • • SAW – Submerged arc welding may be the least common robotic arc welding process, but it is the best for thick plate welding as well as longer welds. SAW is still relatively new to welding automation, with it only getting its start with industrial robots in the last ten years.

Continuous arc welding?

Submerged Arc Welding (SAW)

A frequently-used process with a continuously-fed consumable electrode and a blanket of fusible flux which becomes conductive when molten, providing a current path between the part and the electrode

The four main types of welding are: Gas Metal Arc Welding (GMAW/MIG), Gas Tungsten Arc Welding (GTAW/TIG), Shielded Metal Arc Welding (SMAW), and Flux Cored Arc Welding (FCAW).

Spot welding

Spot welding is a type of electric resistance welding used to weld various sheet metal products, through a process in which contacting metal surface points are joined by the heat obtained from resistance to electric current. 

Use for steel and stainless steel only. For more heat (amperage output), use shorter tongs. For units without a heat control, tong length can be used for a control. For instance, for thin metals

Advantages of Spot Welding

The process can be easily automated through the use of welding robots. Multiple metal sheets can be joined at the same time. No filler material is consumed, unlike some other methods (MIG welding). Cost-effective and economical as it doesn’t use inert gases or filler metals.23-May-2022

Spot welding (also known as resistance spot welding) is a resistance welding process. This welding process is used primarily for welding two or more metal sheets together by applying pressure and heat from an electric current to the weld area.

3 stages of spot welding?

Spot Welding

Electrodes seated in a weld head are brought to the surface of the parts to be joined and force (pressure) is applied.

Current is applied through the electrodes to the workpiece to melt the material.

Current is removed but electrodes remain in place at force to allow the material to cool and solidify.


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