Benefits of Using Cobots (Collaborative Robots) for Welding Applications

October 2022

The trend for industrialised automation has boomed in recent years, and to date, there are over 50,000 cobot installations. Since 2017, this number of cobots in use has more than doubled, with operations managers in over 55 countries worldwide favouring their use.

The electronics and automotive industries are the leading sectors thanks to the numerous benefits of using cobots (collaborative robots) for welding applications. Robot efficiency has vastly improved in recent years by working seamlessly side-by-side with employees to deliver a fast ROI.

If you work in the welding industry, you might be thinking of incorporating collaborative robots to increase your company’s productivity. In the coming years, it is predicted that most manufacturing companies will be making the transition to the use of cobots to scale their output.

In this article, we go into the benefits of using collaborative robots in the workplace and why you shouldn’t ignore their use.

 

Cobots vs Robots

Although similar in helping to assist a human with a task, a robot and a cobot differ in how they do this.

A robot is an autonomous machine. Once programmed, it performs a task without the need for human control.

A cobot is also programmable; however, it makes use of artificial intelligence. It’s a robot that performs a task in collaboration with a human engineer and, more so, works alongside them.

Cobots have integrated safety features that let them work right next to their human colleagues. This is in sharp contrast to traditional industrial robots, which can be dangerous and require specialised safety features such as fencing that takes up valuable floor space.

 

Who Should Use a Cobot?

Cobots are suitable for most sized manufacturers, especially if you’re a medium-sized business looking to automate production and increase output. Traditional welding robots are not the best option for high-mix-low-volume production; this is where the use of a cobot comes in.

Smaller welding companies can also take advantage of the use of a cobot to help grow their output through consistently high-quality work, with the ROI being returned within just a few years.

 

What Are Collaborative Robots?

A collaborative robot is a robotic arm paired with end-of-arm tooling. These tools can be sensors, grippers, or welding equipment. They can be easily programmed to work in collaboration with humans, hence the name. The cobot and human can exist close to each other, unlike a traditional robot.

 

Benefits Of Using Cobots (Collaborative Robots) For Welding Applications

If you’ve worked in the industry for any amount of time, you’ll be all too familiar with welding automation that typically involves a six-axis industrial robot. As great as these are, they do have their limitations. The new way of integrating automated welding applications is through the use of cobots. Here are some of the benefits of cobots and why you should consider cobot welding.

 

Quickly Programmed

A traditional industrial robot can sometimes require a lot of technical know-how along with the time taken to programme actions. Furthermore, they are often limited to performing just one action.

An industrial welding robot requires coding in its native language to reprogram. This process can take days to weeks and is often done by external robot programmers. This is a costly and slow process.

In comparison, a cobot is easy to program, operate and redeploy. Tailor-made welding software for cobots like SmoothTool from the company Smooth Robotics makes programming a weld extremely easy. No coding is required as you simply teach the cobot where to weld by setting some points along the desired welding path. This means that reprogramming can be done in minutes instead of days and that it can be done by your own welders.

All the programs created by a welding cobot can be saved and used again at a later date. Moreover, each welding program can be easily copied and offset to a new position. This makes it very easy to set up batch welding.

 

Fast Installation

In the past, the installation of a robot could take days before it was effectively up and running. In contrast, a cobot is easily set up and ready for use within an hour, thanks to its user-friendly software.

This means a cobot can be set up and used alongside the existing team as a flexible employee to undergo a range of tasks across different departments.

 

Use Across Different Departments

We already touched on this briefly in the section on fast installation. Because a cobot works more like a flexible robot, new tasks can be added to it simply and efficiently. The cobot is designed to work alongside employees so it can move between different departments when needed.

The flexibility also allows for employees to assign the cobot to help with peak production times and to assist a team where the workload is greatest. The process engineers could then assign the cobot to a different team when the priority workload shifts.

Cobots can be used with a wide range of welding processes, including automated laser, MIG, TIG, and plasma welding.

 

They Are Consistent and Accurate

A cobot can perform actions with an accuracy of up to 0.1mm with consistency. Tasks can be set to be performed with the same tolerances, including tension, speed and pressure. This ensures continuity throughout tasks.

Similarly to regular welding robots, a cobot can provide a precise, continuous, and steady motion when welding. This gives a smoother and stronger weld seam. Cobots are also able to produce longer welds without the need for multiple stops and starts; this also helps to improve weld quality.

A cobot can easily switch between automated low-volume and high-mix productions, each with an accurate output.

 

Positive Effect On Employees

As the name says, cobots are designed to work alongside employees and not replace them. They have a people-focused role and assist staff by making their work easier and more efficient.

A cobot can be left to complete a monotonous or repetitive task, which frees up the employee to focus on something else further down the production line, which boosts productivity.

The use of a cobot to complete monotonous tasks can also help to prevent RSIs (repetitive strain injuries) which is a condition that occurs when the same movement is performed for a long time.

An employee with an RSI will need to take time off to recuperate. Using a robot to complete repetitive tasks can mean there’s less chance of these types of injuries happening, and therefore will mean less absenteeism.

Manual welding can be hazardous. Welders deal with extreme heat, electrical power, loud noises, and toxic fumes when doing traditional manual welding. By using a cobot to automate the actual welding, the human welder can minimize or eliminate many of these health hazards. This will lead to fewer workplace accidents and healthier employees.

 

Happier Employees

Because employees feel supported in the work they are carrying out, the stress of having too much work to complete is alleviated as it can be delegated to a cobot.

When the monotonous tasks are delegated to the cobot, the employee has more time to think about the more creative and solution-oriented thinking tasks. When a worker is engaged in their work, it produces a happier work environment and has a positive impact on their well-being.

An employee can also use the gained time from delegating a task to a cobot to focus on upskilling for more rewarding roles within the company.

 

Increased Productivity and Process Optimisation

The primary goal for the robotisation of a process is to optimise the outcome. The use of cobots can assist with minimising errors and create a greater product yield by up to 85%.

A skilled employee can be freed up from a necessary but simple task to work on other areas in the production line.

 

Reduce The Amount Of Guarding Required

With a traditional robot welding system, various safeguarding practices have to be in place, such as interlocked safety fences and expensive guarding. Cobots have the advantage of already having a lot of in built safety as standard, therefore potentially saving you time and money.

Although in most applications, cobots can run unguarded due to their integrated safety sensor that can detect collisions, it may, however, be deemed necessary to add additional safety scanners. These scanners can be integrated into the UR controller very easily. The addition of such safety devices ensures that safe zones are established, ensuring a very controlled and safe environment.

 

With any welding systems, it would also be advisable to install appropriate protective screens or curtains to help eliminate the chance of Arc-Eye or Welder’s Flash.

 

Eliminate the Need for Safeguarding Equipment

With a traditional robot welding system, various safeguarding practices have to be in place, such as area scanners and safety fencing. One of the biggest advantages of using a cobot is that they are designed to be used safely around humans without the need for barriers.

A cobot has integrated sensors that can detect people and other objects and are programmed to slow down or stop when something is in their work area. They also feature a rounded edge exterior and have no pinch points, ensuring that the cobot and employee can work closely with each other.

 

Space Saving

Cobots are compact in size, twin that with the point we mentioned about not needing safeguarding equipment, and you’ll find they take up significantly less space than a traditional robot.

The small footprint of a cobot compared to a traditional welding robot means they are much more versatile at being located in a workspace. They don’t need a designated work cell and can easily be relocated when production needs change.

 

More Affordable

When welding application is automated with a collaborative robot, it can be surprisingly more affordable than using a traditional industrial welding robot that needs additional equipment, such as safety equipment.

Also, a cobot can save business money as the software is much more intuitive compared to a traditional robot. This means less time and money is lost through specialist training courses.

 

 

Thinking of Using a Cobot?

SP Automation & Robotics is one of the longest-established automation manufacturers in the UK. We have been serving a vast range of industries for more than 35 years.

Automation has never been easier. If you want to find out more about the benefits of using cobots (collaborative robots) for welding applications or any other industry, contact our knowledgeable engineers today. They’ll tell you everything you need to know how about how to get started with cobots.

 

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