Welding Robots

Typical Process Steps in Automated Welding

Positioning of the Workpiece

The component to be joined is precisely positioned in the fixture to ensure reproducible alignment for the welding process. Depending on the degree of automation of the production line, this can be done manually, semi-automatically, or fully automatically.

Programming the Welding Path

The welding path is defined either through online teach-in directly at the robot or via offline programming in a simulation environment. All relevant process parameters,such as welding speed, arc length, current, and seam trajectory are determined and optimized.

Automated Execution of the Welding Process

The robot autonomously performs the selected welding process according to the programmed sequence. Movements, welding parameters, and cycle times are executed to guarantee consistent weld quality.

Quality Assurance via Sensors and Machine Vision

Integrated sensors and camera-based systems monitor the welding process in real time. They record parameters such as seam position, temperature profile, or arc characteristics, enabling immediate process correction or subsequent quality evaluation.

Thanks to standardized and precisely coordinated process steps, robotic welding systems can operate continuously with high reproducibility. This ensures consistently high seam quality — both in large-scale production and in variant-rich or customized manufacturing orders.

Benefits of Using Welding Robots

The use of robotic welding systems offers a wide range of economic and production-related advantages for companies of all sizes. By automating welding processes, productivity and process stability can be significantly increased. As a result, weld quality can be maintained at a consistently high level. Modern welding robots are characterized by high precision, repeatability, and reliability, clearly outperforming manual processes in terms of seam consistency, process safety, and cycle time in series production.
 

Summary of Key Advantages: 

• Consistent weld quality: Each weld is executed with uniform precision and under defined process parameters.
• Cost reduction: Minimization of rework and scrap through reproducible and stable welding processes.
• Workplace safety: Reduction of physical strain and exposure of employees by shifting hazardous tasks to automated systems.
• High flexibility: Adaptability to different workpiece geometries, materials, and welding methods thanks to modular system architecture.
• Process efficiency: Especially in serial production, short cycle times and high throughput rates lead to a significant increase in overall productivity.

Selection Criteria for the Use of Welding Robots in Industrial Manufacturing

The increasing automation of industrial production processes presents companies with a strategic decision: whether and to what extent robotic welding systems should be integrated into their manufacturing operations. Selecting the right welding robot is not an isolated investment decision but part of a comprehensive process optimization strategy that must consider both technical and economic factors.

Central criteria is the geometry of the component and the frequency of repetition of the welding tasks. Workpieces with standardized geometries and high production volumes are particularly well suited for automated welding, as they allow reproducible seam tracking and efficient programming. At the same time, the chosen welding process — whether MIG/MAG, TIG, laser, or spot welding — must be compatible with the materials used and the required quality standards.

Another key selection factor is quality assurance.Modern welding robots can be equipped with sensor and vision systems that monitor and document the welding process in real time. This enables continuous process control and ensures compliance with industry-specific standards and certification requirements.

The production volume plays a decisive role in evaluating the economic feasibility of a welding robot system.
In high-volume manufacturing, the focus is on maximum process efficiency: welding robots allow short cycle times, high throughput, and consistent seam quality.

Automation optimizes cycle times and significantly increases overall productivity. In such environments, the investment in a robotic welding system often pays off quick particulary when the production line is designed for large quantities and low product variation. In contrast, high-mix production environments such as special-purpose machinery or general metalworking require maximum system flexibility.

Modular robotic solutions with interchangeable welding tools, adaptable fixtures, and intelligent control systems enable rapid changeovers to different component geometries and welding processes.

The ability to create and simulate programs offline further reduces downtime and increases equipment availability.

Thus, the decision to implement a roboticwelding system must always be made in the context of the planned production volume and product variety. While cycle time optimization is the primary goal in highly automated mass production, adaptability and scalability are key success factors in flexible manufacturing environments.

For the efficient integration of welding robots into existing production systems, seamless connectivity to higher-level automation and IT infrastructures is essential. This includes integration with machine controls (e.g., PLCs), Manufacturing Execution Systems (MES), and Enterprise Resource Planning (ERP) platforms. Integration into automated production cells and linked manufacturing lines is also critical for scalability and overall equipment effectiveness (OEE).

An innovative approach to simplifying this integration is the use of controller-independent robotic systems, also referred to as open robotics. These systems are characterized by their ability to be directly integrated into existing machine and process controls without requiring proprietary robot controllers. By using standardized communication protocols such as OPC UA, Profinet, or EtherCAT, they enable end-to-end data and control transparency across all levels of the automation pyramid.

Open robotics solutions therefore offer high interoperability with existing system components while reducing integration effort and complexity in retrofit projects or expansions. They make a significant contribution to increasing the flexibility and future viability of production infrastructures and enable cost-efficient implementation of modern Industry 4.0 concepts.

Maintenance and Servicing of Welding Robots

Regular maintenance is essential to ensure the longevity and reliability of a welding robot.

As part of preventive maintenance, mechanical components such as gear units, axes, and welding guns are systematically inspected, cleaned, lubricated, and replaced if necessary.

Electrical assemblies, control units, and all cable and connector systems are also subject to periodic inspection to identify potential failure risks at an early stage and avoid unplanned downtime.Special attention is given to the maintenance of torch and nozzle components, as wear, deposits, or contamination can significantly affect weld quality.

Leading manufacturers offer automated cleaning and calibration systems integrated directly into the production process, ensuring consistently high process quality.

A consistent and well-documented maintenance strategy not only minimizes downtime and maintenance costs but also sustainably improves overall equipment effectiveness (OEE) and the return on investment (ROI) of welding robot systems.