Getting Started with Cobot Welding

What is a Cobot, and Can You Work with One?

Cobots are easier to use than traditional industrial robots (IRs) because they include options for hand guiding, and have generally more simple and intuitive programming. This makes them a lot more accessible to people who do not have a robotics or programming background. Because they can be hand manipulated, the experience of programming is more physical than traditional coding. Sometimes, programing a cobot is described as the user speaking human language to the robot, rather than us learning the robot’s language.

To program a cobot welding application, it is far more important that the user be a competent welder, rather than robotically savvy. Power/mation is happy to get an operator, engineer, or welder up to speed with our cobots.

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Benefits of Cobot Welding

Easy to use

Creating a new welding path is much faster in a cobot than it is with a traditional IR. Since cobots have the advantage of hand guiding and jogging, you get the best of both precision hardware and an easy to manipulate tool.

Flexible

Because welding paths can be created very quickly, and easily stored to be recalled later, the cobot can be used for many operations. The robot arm is also easy to repurpose! If you finish a big, repetitive weld project, you could install alternative end of arm tooling and move it to complete another task, like machine tending, in another part of your facility.

Increase Productivity

By using robotics, welds can be even more consistent than when done by an experienced welder. This frees your welders up for other tasks that cannot be completed with a robot. This also creates less faulty parts overall. By having a robot weld, you also cut down your active labor time on a given part. This frees an operator to do finishing tasks, load another part into a different robot cell, or take a break and come back to the robot when the weld is finished.

Safety in mind

Cobots are built with force sensing technology. This means that with the right safety settings programed into the robot, it will stop when it collides into an object, or an object collides with it. If a person were to interact with a cobot during a welding operation, they would still need to be aware of the hot weld torch, but the robot would not continue once its path was interrupted.

What Makes an Ideal Application?

Cobot welding excels in scenarios involving small parts in large quantities, such as brackets, stands, and small automotive components. It is equally valuable for larger parts that require exceptional consistency, including large frames, agricultural items, and metal forms. Cobot welding is particularly advantageous for tasks involving long, straight seams that would be physically demanding for a human welder. For these longer or larger weld paths, cobots can be placed on a 7th axis, although it’s important to note that the 7th axis is not collaborative in nature.

Lots of Options in Between!

Cobot welding is versatile and adaptable, making it suitable for a wide range of applications. If your skilled workforce encounters welding challenges, cobot technology can be evaluated as a solution.

Examples of Cobot Welding

Cobot hand guided path using teach pendant

Hand-Guided Welding – In this example, the operator is hand-guiding the cobot’s welding path using the teach pendant on the floor. Multiple small parts are being welded simultaneously on a larger welding table.

bracket being welded with a smaller cobot

Medium-Sized Bracket Welding – This image showcases the welding of a medium-sized bracket using a smaller Cobot.

Small/Medium Weld Cell – In this scenario, a small to medium-sized weld cell is employed, with protective measures in place to prevent issues such as weld splatter or operator interference. The system incorporates various accessories, including a hose package and a weld table with adjustable bracketing.

7th Axis (Robot Transfer Unit) – Macron Dynamics – In this scenario, a small to medium-sized weld cell is employed, with protective measures in place to prevent issues such as weld splatter or operator interference. The system incorporates various accessories, including a hose package and a weld table with adjustable bracketing.

How does Cobot Welding Work?

Current Capabilities

Cobot welding primarily involves MIG welding, with stick or spot welding not currently available with cobots.

Key Components

A cobot welding system requires the following main components:

Cobot
Weld Table
Weld Torch designed for robotic welding
Weld power supply and wire feeder

Weld Schedule Control

Depending on the system configuration, either the welder power supply or the robot controller can manage the weld schedule. Analog and digital commands can be transmitted through the robot power supply, and Ethernet IP commands are also possible via an interface box.

Get Started

To kickstart your cobot welding journey:

Discuss interface and welder options with Power/mation.
Provide detailed part information, including drawings, images, measurements, or samples for evaluation.
Schedule training sessions with Power/mation to prepare your team for successful cobot welding. Additionally, consider contacting your local welding distributor for supplementary welding training as needed.