Robotic welding technology has emerged as a critical metal processing technology in high-speed manufacturing. With its numerous advantages over traditional manual welding techniques, robotic laser welding machines have revolutionized the way metal components are fabricated and assembled. In this article, we will explore the latest trends and developments robotic laser welding in manufacturing, highlighting the significant advancements that have further enhanced accuracy, efficiency, and productivity.
Part 1: The Difference between Laser Welding and Traditional Welding
Welding is an important process method in modern manufacturing, which is widely used in automobile manufacturing. With the progress of science and technology, the welding of metal plates and light metal materials has posed new challenges to automotive welding. Robotics and automated laser welding technology have made great progress in automotive welding technology.
Laser welding is characterized by extremely small part distortion, almost no joint gap and a high weld depth and width ratio, resulting in higher weld quality than conventional welding methods. However, the key to ensuring the quality of laser welding lies in the monitoring and quality control of the laser welding process, which is an important element in the field of laser applications.
To automate laser welding, various sensors such as inductive, capacitive, acoustic and photoelectric sensors can be used and the collected data can be processed by a computer. These sensors can be used for tasks such as weld seam tracking, defect detection and weld quality monitoring. Through feedback control, the welding process parameters can be adjusted to meet different welding objects and requirements.
Therefore, the key to control of welding quality is to monitor the welding process in real time and take appropriate measures to adjust it. By applying advanced sensor technology and electronic computer processing, efficient automated laser welding can be achieved and stable and reliable welding quality can be ensured.
Robotic Welding Trends for 2023: The impact of combining robotics and laser welding technology on manufacturing
Advanced automation and programming capabilities ensure the flexibility and productivity of modern welding operations. The robot can perform otherwise tedious manual tasks and, with the right tools and software, can monitor and optimize welding parameters without stopping the operation.
Part 2: Trends and Features in the Development of Robot Laser Welding
1. Increased Automation: With ongoing technological advancements, robot welding will become more automated and intelligent. Future robot welding systems will possess enhanced sensing and decision-making capabilities, allowing them to adjust and optimize welding processes based on real-time requirements.
2. Collaborative Robots: Collaborative robots, also known as cobots, will play a significant role in the welding field. These robots have safety features and the ability to work alongside humans, enabling them to collaborate in welding tasks. Such human-robot cooperation enhances work efficiency and reduces occupational risks.
3. High Precision Welding: Future robot welding systems will exhibit greater precision and accuracy. By incorporating advanced sensor technology and control algorithms, robots will achieve higher welding quality and precision, making them suitable for complex welding tasks.
4. Flexible Production: With the increasing demand for flexibility and customization in the manufacturing industry, robot welding systems will become more flexible and adaptable. Robots will be capable of swiftly switching welding processes and paths to accommodate various product and workpiece requirements.
5. Data-Driven Optimization: The application of data analysis and artificial intelligence techniques will bring further optimization and improvements to robot welding. By collecting and analyzing a large amount of welding data, robots can learn and optimize welding parameters, paths, and processes, thus enhancing welding efficiency and quality.
6. Adaptive Control: Future robot welding systems will be capable of adaptive control, adjusting and optimizing based on real-time feedback and environmental changes during the welding process. This adaptive control improves the stability and adaptability of the welding process.
7. Efficient Energy Utilization: Future robot welding systems will emphasize the efficient utilization of energy. By adopting energy-saving welding processes and equipment and optimizing the use of welding energy, energy consumption and environmental impact can be reduced.
8. Artificial Intelligence: Welding systems can provide data on welding equipment, processes, and robots, which can be utilized for predictive and preventive maintenance. Real-time data processing allows monitoring of process anomalies in welding applications. Machine learning also utilizes real-time data collection to make decisions and offer recommendations based on data trends, such as replacing welding torch nozzles, changing welding wire, or checking for wire guide slippage, helping to avoid issues.
With the advancements, trends, and integration of automation, robotics, and AI, the future of welding technology is promising. The combination of laser welding, robotic systems, AI and machine learning is transforming the welding industry.
Part 3: Latest Application of Laser Welding Robots
Robotic laser welding machines have been widely used in various industries, such as automotive, aerospace, electronics, and home kitchenware. Among them, automotive industry is one of the main application areas of laser welding robotic. In the metal material processing industry, robotic laser welding technology also has a wide range of applications. Especially in the processing of materials such as steel structures and aluminum alloys, robotic laser welding technology can achieve high speed and high quality welding, thus effectively improving production efficiency and product quality.
Industrial Robot Laser Welding Technology in Automotive
The main task of industrial welding robots is to control the motion position, attitude, seam tracking, operation sequence and time of action of industrial robots in the working space, with simple programming, software menu operation, friendly human-computer interaction interface, online operation tips and easy to use, etc.
Robotic laser welding has been widely used in the automotive manufacturing industry, such as welding of car chassis, seat skeleton, rail, muffler and torque converter. The welding quality of the car body parts directly affects the safety performance of the car. After the application of robot welding, it greatly improves the appearance and internal quality of the welded parts, and ensures the stability of the quality and reduces the labor intensity and improves the labor environment.
Robotic welding for Shipbuilding
Robot laser welding machine provides efficient, precise, and reliable solutions for various applications in the shipbuilding industry.
1. Ship Hull Welding: Robot laser welding is used to connect ship hull panels, frames, structures, and components during the manufacturing and assembly process. Given the high requirements for hull strength and sealing, robot laser welding ensures high-precision welds, ensuring the stability and quality of the ship hull. It also reduces deformations and defects while improving the consistency and aesthetic appeal of the welds.
2. Ship Pipe Welding: In the ship’s piping systems, robot laser welding is employed to weld connection points of pipes such as water supply, fuel, and gas pipes. Robot laser welding technology achieves high-quality welds, ensuring the tightness and reliability of the pipes. Moreover, it can handle complex pipe layouts and multi-layered pipe connections, improving construction efficiency and reducing human errors.
3. Ship Repair and Maintenance: Robot laser welding technology is utilized in the repair and maintenance processes of ships. It is used to repair damaged sections of the ship’s structure, replace damaged hull plates, and weld new structural components. The high precision and repeatability of robot laser welding enable precise and efficient repairs. Additionally, robot laser welding allows for non-contact welding, minimizing further damage to the ship’s structure.
By applying robot laser welding technology, the shipbuilding industry can achieve higher production efficiency and quality standards. It reduces the labor-intensive nature of manual welding, enhances work safety, and ensures consistency in ship construction.
Robotic Laser Welding for Metal Fabrication
Robot laser welding technology plays a crucial role in metal processing applications, particularly in metal product manufacturing and steel structure construction.
In the field of metal manufacturing, robot laser welding is utilized in the production and assembly of various metal products. For instance, in the furniture industry, robot laser welding is employed to connect metal frames and components, ensuring robust structures and aesthetically pleasing welds. In the kitchenware manufacturing industry, robot laser welding is used to weld components of cookware, utensils, and other metal appliances, providing durable and long-lasting connections.
In the construction of large steel structures such as bridges, stadiums, and high-rise buildings, robot laser welding enables efficient, precise, and high-strength welding connections. By utilizing robot laser welding for metal welding, efficiency can be increased, and the structural integrity and safety of the buildings can be ensured.
Part 4: 6 Axis Double Station Laser Welding Robot
Robot laser welding technology enables high-precision welding, reducing human errors and poor weld quality while enhancing product quality and consistency. Additionally, robot laser welding is characterized by high quality and speed, allowing for the rapid completion of welding tasks and improving production efficiency and capacity.
Therefore, the application of laser welding robot in metal processing production brings significant benefits to the manufacturing industry. It drives process improvements, boosts production efficiency, and ensures product quality.
Six-axis laser welding robot with linked robot arm is a kind of laser welding equipment that couples a high-energy laser beam into an optical fiber, transmits it over a long distance, collimates it into parallel light through a collimating mirror, and then focuses on the workpiece to implement welding. The robot arm with fiber laser welding machine can weld any angle, any arc, spherical surface, concave and convex surface of complex workpieces. It can realize automatic welding of any trajectory such as spot welding, linear welding and circumferential welding.
1. Occupies less space, offering higher cost-effectiveness and competitiveness, enabling production automation and intelligence.
2. Dual-station configuration suitable for batch production of workpiece welding.
3. Whether for production start-up or line changeover, robot programming can be prepared in advance, significantly reducing the time required for on-site debugging and production interruption, thereby improving production efficiency.
4. Reduces operation costs, enhances product quality and consistency, improves working conditions for employees, expands output, reduces raw material waste, and improves the yield of good products.
5. For welding in hard-to-reach areas, flexible transmission and non-contact welding provide greater flexibility. The laser beam can be split in time and energy, allowing for simultaneous processing with multiple beams, providing conditions for more precise welding.
Advantages of Six-Axis Robot Welding System:
1. The fiber laser has a very small spot size, minimal heat affected zone, low deformation, and ultra-fast welding speed.
2. The fiber laser has a lifespan of 100,000 hours and requires little to no consumables, making maintenance more convenient.
3. The power supply converts 40% of energy into laser power, resulting in energy-saving and efficient operation.
4. The CCD monitoring system allows clear observation of product positioning and welding effects using red light indicators.
5. The fiber laser supports multiple welding modes, allowing flexible switching between modulation and continuous modes based on product requirements.
6. It enables flexible and high-quality welding through non-contact welding in precise and hard-to-reach areas.
(Primarily applicable to mass welding of stainless steel, carbon steel, and aluminum alloys between 0.6-5mm)
1. Multiple products can be welded on the same side without restrictions, and flexible welding can be done in a left-right or L-shaped manner, allowing simultaneous feeding and welding.
2. It can replace traditional welding methods, reducing the need for polishing. Laser welding has 2~5 times the efficiency compared to traditional welding methods.
3. Compared to gantry platform welding, the cost is comparable, but with more axis and flexibility. Using a robot can be considered when appropriate.
4. Two robots can simultaneously weld the same large-sized product.
5. It can be used for industrial upgrading and environmental transformation, such as welding for photovoltaic solar energy cabinets.
6. It can be used for welding pipes at different angles, such as electric motorcycles, furniture, and more.
This equipment is applied in the welding of large and medium-sized shells such as automotive components, motorcycle frames, range hoods, ovens, bathtubs, water tanks, and lithium battery casings.
In the future, the development trends of welding robots will bring about significant changes in the field of metal processes. To address the shortage of skilled welders, more and more companies will adopt robotic welding and collaborative robotics. The automation capabilities and high-precision welding technology of robotic laser welding machines will be one of the solutions to fill the shortage of welders. By introducing robotics, it will increase productivity, reduce manual errors and waste, and ensure consistent and consistent weld quality.