Welding Robots
Suzhou Gulas Robot Automation Technology: an Innovative Welding Robots Manufacturer
Our team is a steel team with a common dream. Among them are thoughtful planners, experienced marketers, and strong leaders.
Variety of Products
We can manufacture handling robots, welding robots, grinding robots and other industrial robot automation system integration applications for customers. We can also provide customers with robot pipeline kits, robot positioners, robot sensors, robot positioning tracks, robot bases and other products.
Rich Market Experience
Our products are widely used in the fields of device intelligence and cloud services, electronic 3C, and medical industries. Our products have also received favor from overseas markets, such as Japan, Taiwan, South Korea and other countries and regions.
One-Stop Service
We provide digital one-stop solutions and undertake robot automation production line integration and transformation projects. Our one-stop service also includes industrial robot installation and commissioning, after-sales service and maintenance, etc.
Multiple Technical Certifications
We have obtained many patent certificates such as robot design and debugging engineer, electrical automation design and debugging engineer, mechanical design engineer, and IT engineer. Our company is also a member of the Suzhou Robot Association.
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Brief Introduction to Welding Robots
Welding robots enable fully automated welding processes. Typically, loading the ingots into the furnace is the only human involvement in the process. Robotic welding is becoming increasingly popular because of its largely human-independent process. The most common robotic welding machinery consists of two main components: the mechanical unit and the controller. Mechanical units operate on materials or parts to create components or products. The controller is considered the "brain" of the device as it makes the device's arms move according to the design implemented in the system. The device's movement can be pre-programmed or guided by machine vision, an automated inspection and analysis technology based on imaging. The unit can also be programmed using a combination of both methods.
Benefits of Welding Robots
The most important aspect of a weld is its level of quality. Before hiring a professional welder, businesses will test the welder to check their weld quality. As humans, even the most efficient and experienced welder may experience hiccups in their welding. While these inconsistencies may be small or mild, they can affect the durability of the final product. Robotic welding produces high-quality and consistent welds, every time. The weld quality of the robot, however, will depend on the workflow and the quality of the materials. Once you systemize your welding processes, a welding robot can create high-quality welds more efficiently than the most experienced professional welders. This will improve efficiency and lead to more advantages.
Robotic welding systems work much faster than any skilled human welder. The advantage here is robotic welding will save you time. Welding mistakes are one of the biggest time-consuming problems businesses face. Robotic welding produces fewer mistakes than manual welding which saves you time and money on rework. Human laborers require breaks, vacations, sleep, and more. Robotic welders, however, can work around the clock to continue producing high-quality products. This allows you to complete more projects and products in less time.
The cost of hiring a welding professional and keeping them safe is expensive. Besides paying them a wage, businesses must offer their employees benefits, health insurance, safety insurance, and vacation time. While the upfront cost of a robot isn’t cheap, it will cost a business less over time. Welding is a dangerous and potentially hazardous career. Human welders need proper safety gear and skills to safely weld. Robotic welders don’t require the same safety gear as humans to produce welds which will cut safety costs. Most welding robots can endure greater hazards while maintaining consistent production. Robotic welders will lower insurance costs and reduce the chances of a dangerous accident.
Mistakes will happen and they’re much more frequent with human welders. Over time, these mistakes will add up in the forms of wasted materials and reworks. These two issues will slow down production and increase your business’s materials cost. Do you want to reduce waste while improving production? The solution is a robotic welder. With proper programming, robotic welding will produce accurate welds every time. This will lower waste and conserves valuable materials. By consistently running, welding robots can lower energy costs as they aren’t constantly starting up between projects. Your business can introduce robotic welding slowly by starting with a single robot spot welding process. If you find robotic welding works great for your business, you can upgrade to multiple welding robots to automate your entire welding process.
Since robotic welding can continue working around the clock, you can enjoy a greater level of productivity. Adding robotic welding to your current production will streamline processes. Human employees can focus on other important tasks that are less dangerous and hazardous. In turn, this will allow your business to enjoy a higher production yield. Higher production will boost sales and give you a competitive edge.
Speaking of competitive edge, investing in new welding technology will make you stand out from your competition. The most notable benefit is you’ll have the ability to produce a greater number of products in less time. You can expand your market to potential customers who need on-demand and custom welded products. Many customers and businesses will find your company to be more innovative and resourceful. Your company will get products to customers faster will make your business more desirable than others in your industry.
Different Types of Welding Robots
Resistance Spot Welding Robot
The automotive manufacturing industry commonly uses resistance spot welding. It’s a resistance welding process that uses larger electrical currents to join two or more sheets in a single location. Spot welding robots are articulating robots. They are robots that have rotary joints that have a range of anywhere from two to 10 axes. Spot welding robots have a servo motor equipped with a high-resolution encoder that accurately controls the motion of the spot welding gun. The welding gun has a pair of electrodes that can open and close. It also comes with software that controls the acceleration, position, and force of the robotic arm.
Collaborative Welding Robot
Collaborative robot welding, or cobot welding for short, is also a robotic arm, usually 6-axis, with a welding torch as its end effector. Unlike industrial robots, cobots can work alongside humans. Because of this, there is no need to house them in a welding robot cell. You can only take care of the welding safety (flash, splatter). They are also easy to deploy and redeploy to different tasks. With the advent of collaborative robots (or cobots), medium-sized welding businesses can also benefit from welding automation. They are also easier to program.
Shielded Metal Arc Welding Robots (SMAW)
Shielded Metal Arc Welding (SMAW) is also called stick welding. In this type of welding, an arc is created between a consumable flux electrode and the welded material. A SMAW robot needs to consider a variation of the tool center point (TCP). A TCP is a variable used in robots for the computer to keep track of the tip of the tool, here the consumable electrode. The consumption rate of the electrode determines the direction of the robotic arm.
Gas Metal Arc Welding (GMAW/MIG) Robot
Usually, robots are used for GMAW welding when high deposition rates are needed to get a high production rate. In GMAW welding or MIG welding, a consumable electrode is melted and acts as a filler material. Robotic GMAW welding or robotic MIG welding is used for welding stainless steel, copper, nickel, carbon steel, and aluminum. It’s usually used for metals that have high melting points of conductivity.
Gas Tungsten Arc Welding (GTAW/TIG) Robot
Gas tungsten arc welding (GTAW) robots are used when welding thin parts or wanting aesthetic and precise welds. In Robotic GTAW, variables such as torch movement, shielding-gas pre flow, pulse frequency, etc., are automatically controlled. Arc length can also be automatically maintained with automatic voltage control. Intelligent GTAW robotic welding systems have cameras that help with joint location tracking and error detection. In this type of system, the operator calibrates the camera and teaches the robot the weld path. The robot then takes a picture before the arc is established and compares this image to the reference image. This type of system is ideal for welding thin materials where the placement of the arc plays an important factor.
Laser Welding Robot
A laser welding robot is a type of welding that uses a focused laser beam as the energy source. Laser welding can either be through heat conduction or deep laser. The robot laser welding machine is composed of a fiber laser head, a tracking system, a fiber laser, and an industrial robot. It’s usually used to weld materials of different thicknesses from different angles and different directions. Medical devices and the aerospace industry typically make use of robot laser welding.
Plasma Welding Robot
This type of robot welder uses a plasma arc as the heat source to melt the junction of the two metals that needs welding. Plasma welding robots are equipped with a plasma torch. A tungsten electrode is suspended inside the torch. The electrode compresses the arc, so the plasma flows from the torch at high speed. Plasma welding robots usually make use of six-axis articulated robots. Plasma robots are used for welding a variety of metals regardless of their thickness. Robotic plasma welding is well known for precise welds and short cycle times. These robots can also weld both narrow and welds without part distortion.
Welding Robots Technical Parameters
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Model |
CRP-RH18-20-W |
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Arm form |
Vertical multi joint |
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Degree of Freedom of Action |
6-axis |
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Maximum Load |
10KG |
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Stroke |
1-axis |
formal dress/inversion-165°~165° inversion-30°~30° |
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2-axis |
-155°~105° |
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3-axis |
-170°~240° |
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4-axis |
-190°~190° |
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5-axis |
-90°~110° |
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6-axis |
-210°~210° |
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Maximum speed |
1-axis |
160°/S |
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2-axis |
160°/S |
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3-axis |
169°/S |
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4-axis |
301°/S |
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5-axis |
342°/S |
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6-axis |
708°/S |
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Allowable torque |
4-axis |
55N.M |
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5-axis |
55N.M |
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6-axis |
24N.M |
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Allowable moment of inertia |
4-axis |
2.1kg.m² |
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5-axis |
2.1kg.m² |
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6-axis |
0.9kg.m² |
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Repeatability |
±0.08mm |
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Maximum coverage |
1730mm |
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weight |
285kg |
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Installation method |
Ground/Top mounted/hanging |
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Installation environment |
ambient temperature |
0~45℃ |
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relative humidity |
20-80% |
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|
vibrate |
Below0.5G |
|
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other |
The installation site of the robot must be far away：Flammable or corrosive liquids, electrical interference sources |
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IP registration |
Wrist IP67，other IP54 |
Applications of Welding Robots
MIG Welding
Metal inert gas welding is one of the most popular types of arc welding processes and is extremely easy to automate with robots. During MIG welding a consumable electrode is continuously fed through a welding gun forming an electric arc between the wire and metal workpiece, causing the metals to melt and join together. Many manufacturers turn to MIG welding when large workpieces are involved and for when speed is needed. Other advantages of MIG welding include higher quality welds due to the use of shielding gas and the ability to weld thin and thick metals.
TIG Welding
Tungsten inert gas welding is another form of arc welding. During TIG welding an arc forms between the electrode and the workpieces to heat and join them together. Inert shielding gas is applied during this process in order to protect the welding pool from contaminants. TIG is often the go to choice of manufacturers for welds requiring a great amount of precision. Because TIG is a precision driven process it is slower than other forms of welding and requires great skill and control. This is why automating TIG applications with robots has become so popular. Robots ease the complexity and produce strong welds. Robotic TIG welding can be used on almost any metal or alloy, on thin metals, and on small intricate parts.
Plasma Welding
Plasma welding is another type of arc welding in which an electric arc heats inert gas to form plasma. This plasma is then applied to the metal workpieces to melt and bond them together. Plasma welding is ideal for producing clean and precise welds which is why it is commonly used. The small heat affected zone and containment of the arc within the welding torch prevents distortion of the workpiece allowing for seamless welds. Plasma welding robots can complete welds with one pass and provide flexibility with temperature and velocity adjustments.
Spot Welding
Robotic spot resistance welding is heavily utilized amongst the automotive industry and is considered the most economical robotic welding application. During this process metals are joined together through heat produced from the resistance to an electrical current. As the name implies spot welding targets a specific “spot” of the workpiece, preventing excessive heating of the rest of the metal. This is why robots can often be seen spot welding car frames on automotive production lines. The accuracy and high level of repeatability provided through the use of robots is why robotic spot welding has become so commonplace.
Top 5 Costly Mistakes to Avoid When First Buying a Welding Robot
Don’t Choose a Robotic Welder that Requires a Ph.D. to Program
Not all automated welding systems are created equally. Many industrial welding robots require sophisticated programming skills and robotics experts to set up and operate. Moreover, complex automated welders lack flexibility. Manufacturers that specialize in high-mix, low-volume productions will undoubtedly experience lags in throughput due to endless programming and reprogramming. Traditional robots also require weeks of training off-site for the employees, which is costly and forces them to be removed from daily production lines where they are desperately needed. In order to eliminate the need for robotics specialists and programming, opt for a welding robot that requires little programming, which will definitively help onboard your current welding teams that may be concerned that their jobs are at risk.
Resist the Temptation to Build an Automation Team Right off the Bat
An offshoot problem of acquiring an overly sophisticated automated welding system is needing skilled robotics professionals to integrate, program, operate, and carry out maintenance on the equipment. Robotics experts are even harder to find and retain than your standard welders. When starting out in welding automation, avoid hiring a programming team. Don’t run off hiring multiple people right at the start; you may not know who you need and onboarding the wrong staff or too many employees can be a costly endeavor no business needs. Heck, that is why you are investing in robots in the first place! Instead, invest in your top welders to upskill them so that they can work with the robotic welder. This will ensure that the robot can be up and running in no time, accelerate production, and boost welders’ job satisfaction. An initial cobot welding project is a learning experience. Start slowly and have a robot “champion” internally help you spearhead your successful transition to robot welding!
Don’t Exclude Welders and Employees from Your Welding Automation Project
Not including your welders and other team members in your welding automation plans is a surefire disaster. Remember, robots may be scary for your employees. As mentioned before, they are likely concerned that their jobs are on the line. They might even eye new technologies with suspicion, and flat-out refuse to work with them. Robots need people to run them! That is why including staff in your project from the start and addressing the objections your welders have are musts. Employees will learn to like the productivity they can have when working with automated welders, particularly if the robotic welding solution you select allows them to work alongside the machine. Your welding team will also appreciate relegating mundane and repetitive tasks to the welding robot so that they can take on more complex and creative work.
Avoid Overdesigning Your Robotic Welding Cell
As manufacturers and fabrication shops evolve towards automation, one of the major pitfalls is scope creep—or the continuous, uncontrolled growth of a project’s scope. Scope creep not only complicates the implementation of a robot welder but also ramps up costs, which in turn will prolong your return on investment. Start your welding automation journey by properly defining a simple project aligned with your specific requirements. This will reduce the need for expensive machine integrations, automated tables, arch seam tracking technologies, etc.
Stay away from Robotic Solutions that Call for Special Fixtures When Starting
When starting with welding robots, you might find yourself needing to design new and more complex welding fixtures. These are additional costs to consider when automating your welding workflows. Moreover, replacing jigs can be technically challenging, especially when a manufacturer or fabrication shop produces a high number of different welded parts. Some collaborative welding robots can be integrated using a business’ existing assets; welding teams can therefore maintain or even increase productivity by reusing the manual jigs they currently have with a welding cobot.
Optimizing Welding Robot Performance: the Importance of Preventive Maintenance
Welding Robot Preventive Maintenance
Because robots are designed to operate at full speed 24 hours a day, 7 days a week, they are designed to require minimal maintenance. This design concept minimizes downtime for maintenance tasks, resulting in seamless production. Striking the right balance in maintenance is crucial, as overmaintenance can cause problems like overlubrication, which can cause more harm than good. Adhering to a well-planned preventive maintenance schedule is just as important for welding robotic systems as using the correct grease. Since these robots are designed to work at full speed 24 hours a day, 7 days a week, they are designed to require minimal maintenance. This reduces the downtime required to perform maintenance. Additionally, the robot may require too much maintenance, which can lead to over-lubrication of the robot. For the operation of a welding robot system, adhering to a preventive maintenance schedule is just as important as ensuring the correct grease is used. Additionally, the uptime and performance of your robotic welding system can be greatly improved through continued scheduled preventive maintenance.
Improve Uptime and Performance
Regular preventive maintenance is the cornerstone of a high-performance robotic welding system. It ensures the system is running at its best, optimizing uptime and performance. Neglecting maintenance can lead to unexpected breakdowns, production delays and increased costs. With regular maintenance, you can extend the life of your robotic welding system, maximizing your return on investment.
Key Preventive Maintenance Steps for Welding Robots
When following a preventive maintenance plan, there are a few simple steps you should check:
Replace Welded Pipes Every Week
For welding robots, the most common wear occurs on the welding lining. If your company runs three shifts of robots, the weld lining should be replaced weekly to eliminate defects during operation. Welding seams are the parts most prone to wear in welding robots. In a three-shift operation, the welding lining must be replaced weekly to eliminate defects in the production process. New weld seams help achieve consistent and defect-free welds.
Cable Inspection
Observe the robot running through the application and note any dragging, rubbing, contact of the cable on the fixture, or any cable movement along the welding cell or any other part of the system. If left unaddressed, these can become problem areas with costly cable maintenance. Worn cables should be replaced and cables secured to reduce excessive wear.
Welding Gun Tip and Nozzle
It is essential to replace the welding gun nozzle every day. Also, check the welding nozzle for buildup of welding spatter, which may impede welding functionality. A new contact tip on the welding gun can correct defects that may occur during the welding process. Using soap bubbles to check for shielding gas leaks ensures a seamless welding process.
Our Certificate
Below are the certificates we obtained:
Cooperating Partner
Our company has reached cooperation with the following brands:
FAQ
Q: What is robotic welding?
Q: How does robotic welding work?
Q: Do welding robots have sensors?
Q: How do welding robots work?
Q: Will robots replace welders?
Q: What sensors do welding robots have?
Q: How do robot sensors work?
Q: How accurate is robotic welding?
Q: What device stops welding robots?
Q: What is the difference between robotic welding and automatic welding?
Q: How fast can a robot weld?
Q: What is an advantage of using robotics in welding?
Q: What are the two most used welding applications for robotics?
Q: What is arc welding robot?
Q: Why is a robot more efficient than a human at welding?
Q: Are there underwater welding robots?
As one of the leading welding robots manufacturers and suppliers in China, we warmly welcome you to buy cheap welding robots made in China here from our factory. All our products are with high quality and competitive price.
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