The new calendar year is underway, and Eddie Hall isn't going to be the only thing from Stoke
on Trent flexing his muscles. Patera Engineering are setting sights on something big! 2018 is certainly going to be an exciting year for us and what can be more exciting than introducing automation into the workshop with a Welding Cell? Sexy stuff right?
We have been working closely with ABB, a pioneering technology leader who are helping us to understand and discover just how amazing a robot can be in our workshop.
So, I have come up with a list of benefits that I feel this piece of kit can bring us and set us apart from our competition.
Increase in Productivity
With a robot's ability to process welded components three to five times faster than humans by operating continuously, withstanding a greater arc on-time and moving quickly between weld joint positions, a robotic welding system can provide substantial increases in output.
Consistent and Repeatability
Manual welding requires a high level of skill as well as concentration to achieve consistency and repeatability. A robotic welder can continue to perform precisely the same weld cycle continuously, 24 hours a day, seven days a week.
Manual welding processes require multiple jigs which are swapped out with each production run. Robots can save valuable time and eliminate tool changes as grippers can grab any part regardless of size or shape, position it on the assembly, and hold it tight during the welding process.
Numerous safety risks exist for welders such as electric shock, exposure to gases and toxic fumes, and welder’s flash burns to the eyes cornea. Robotic welders have proven themselves in reducing the number of accidents to workers in the metal fabrication industry with the number of injuries reported reducing each year.
A robotic welder can achieve superior quality by ensuring the correct welding angle, speed, and distance with repeatability of accuracy. Ensuring that every single welding joint is consistently produced to the highest quality significantly reduces the need for costly rework.
With a shortage of skilled workers, robotic welders will help to overcome this issue. Whilst manual welders will still be required for jobs which have a high degree of customisation, a robotic welder will alleviate issues in busy times by reducing additional hours and the need to hire and train extra staff.
With manual welding, the size of the weld is determined from the operator and could result in a larger weld than required. Robots are programmed to always weld to the correct length and size of the joint requirement, providing significant saving over time and reduce waste.
Reduced Production Costs
Through improvements in quality, consistency and productivity a robotic welding system can deliver parts at a reduced cost. Further saving can also be made through reduced energy consumption and consumable costs.
Increased Competitive Advantage
Implementing a robotic welding solution can set companies apart from the competition by allowing for faster completion and delivery of products whilst ensuring consistent quality.
You can understand why we would be looking to introduce this into our workshop. With the help from ABB and some dedication and hard work, our robotic muscle will soon be flexing!