Advanced Welding Processes: Technologies and Process Control

Welding automation and robotics 219
protect the welder and associated workers are, however, costly and may
complicate the welding operation or involve the use of cumbersome protective
clothing. There is also the risk of human error which may expose welders
and those around them to unnecessary risk.
In addition to these process-related hazards, there are risks associated
with the application; such as welding in confined spaces, underwater or in
radioactive environments. Automation offers a means of removing the operator
from the process- and application-related hazards and, in addition, it offers
the prospect of improving the control of the welding environment.
11.1.2 Product quality
Reproducible product quality may often be difficult to achieve with manual
welding techniques, particularly when advanced materials and complex joint
configurations are involved. Increasing the level of automation can significantly
improve consistency, increase throughput and reduce the cost of inspection
and rejection.
11.1.3 Supply flexibility
It is often easier to match output to demand with automated systems than it
is with labour-intensive operations. This is particularly true in welding situations
where protracted training and qualification of welders may be required before
an increase in output can be obtained.
11.2 Automation options
Welding automation may vary from simple positioners to fully integrated
systems. For clarity, the various options will be discussed under the following
headings:
∑ simple mechanization;
∑ dedicated and special-purpose automation;
∑ robotic welding;
∑ modular automation;
∑ programmable control;
∑ remote-control slave and automated systems.
11.3 Simple mechanization
The most common simple mechanization systems may be grouped under the
following headings:
∑ tractor systems;
∑ positioners and manipulators.