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for multiple jobs; so, depending on
volume, it may be able to handle the
tasks of several fi xed-automation
systems.
A certain volume of parts will justify
the investment of automation for each
company, and an accurate assessment
of goals and workfl ow help determine
what that volume is. If you make only
small runs of parts, automation becomes
more challenging. If, however, you can
identify two or three components that
can be automated, a robot that can be
programmed to recognize those parts
can offer greater fl exibility and may
benefi t even small fabricators who may
not have signifi cant volume of a single
part.
Although a robot is more expensive
than a fi xed-automation system, you
should be sure to consider the cost of
the necessary tooling before deciding
between the two. Fixed automation
systems can become quite expensive
if extensive changes are required to
retool a part to ensure it can be welded
consistently.
READY TO AUTOMATE?
A streamlined workfl ow is one of
automation’s benefi ts. But a smooth
workfl ow requires you to look beyond
the weld cell to ensure your facility
can accommodate a smooth fl ow of
materials. For example, investing in
an automated system to increase
productivity that is placed in a corner
where each part must be handled twice
makes little sense.
You should have a dependable supply of
parts to avoid moving a bottleneck from
one area to another. Also remember
to consider the expected cycle time of
the robot. Can your personnel supply
enough parts to keep up with the
demand of the automated system’s
cycle time? If not, the supply of parts,
including where they are stored and
how they are moved, must be adjusted
for the automation to be successful.
Otherwise, a robot will sit idle waiting for
components to come down the line - a
costly and counterproductive state for
any automated welding system.
You must have the right power and gas
systems in place, or factor in the cost
of implementing these systems. To
move to an automated system, a facility
needs a 480-volt, three-phase power
supply, as well as bulk delivery of gas
and wire. A gas manifold system may
add to the initial cost of automation, but
will minimize downtime for changing gas
cylinders in the long run.
Determining who will oversee the
automated system and providing training
is essential. Most robot OEMs offer a
weeklong training course explaining
how to operate the equipment. This
course, followed by a week of advanced
programming, is recommended.
Because there is more to welding
automation than simply purchasing
a robot, partnering with a competent
integrator or automation specialist can
help ensure success. Your automation
specialist should:
• Help determine if parts are suitable
for automation, and, if not, what
is required to make them suitable.
• Analyze the workfl ow and facility to
identify potential roadblocks.
• Analyze the true costs involved,
including facility updates and
tooling.
• Determine the potential payback
of the automation investment.
• Help identify goals and develop
a precise plan and time table to
achieve those goals.
• Explain automation options and
help select those that best fi t your
needs.
• Help select a welding power
source that has the fl exibility to
maximize travel speed, minimize
spatter, eliminate over-welding,
provide great arc starting
characteristics and increase
fi rst-pass weld quality.
Remember, no single path to successful
welding automation exists, but a wellthought-out
plan that includes accurate
evaluations is a good start to the
journey.
30
indometalworking news Vol. 2 / 2008