The use of spin welding positioners in production facilities has the potential to completely change the company's output, productivity, and financial situation. These auto welding positioners greatly reduce the effort required by workers to access components or weldments that need to be welded. The spin welding positioner makes welding easier and faster for employees, thereby increasing the company's productivity and profits (the same as existing workers).
You will get efficient and thoughtful service from OLIVET.
What is a spin welding positioner?
The spin welding positioner is a welding positioner of the rotation welding positioner so that the welder can easily approach the area that must be welded. They are designed to enable workers to stand in one position and be able to work continuously on level ground, reducing fatigue and increasing productivity while adding comfort to workers. The spin welding positioner grips a component (such as a pipe joint) and can then be moved to allow the welder to continuously weld the joint without breaking in the weld. They are designed to improve welding quality and make welding safer and faster.
Spin welding positioner increases output
One of the biggest motivations for the company to use spin welding positioners is the increase in production they bring. They enable employees to work smarter rather than work harder, and provide better ergonomics, which makes it easier for experienced workers to perform welding and easier for inexperienced workers to learn. When the position to be welded on the component can be placed in a convenient and easy-to-reach location, workers will be able to weld faster, and each welding work will not waste a lot of energy. This can greatly improve the work efficiency of workers, while reducing the workload, enabling them to complete more work in a day, and reducing the possibility of older, skilled workers leaving. If the welding site is brought to the worker instead of getting the worker to the welding site, the manual labor of the job will be greatly reduced.
The rotating type welding positioner greatly shortens the positioning time and makes the positioning time easier. With the old positioning method, positioning the assembly in the correct location can sometimes take several hours and involves the use of multiple workers at once. This is quite expensive for the company because the group of workers cannot produce anything by themselves, because they spend hours just to reach a certain welding area. Spin welding positioners usually require only one worker to complete the same job in a few minutes. This saves working time, increases productivity and output, and frees up other workers to perform other production tasks.
When the spin welding positioner is combined with an automatic welding machine, especially in simple assembly, the output can also be improved. Robot-integrated welders increase productivity by working faster and reducing downtime, and they are consistent. Although humans can weld 12 to 14 inches per minute (IPM), robots can usually weld at least 20 IPM. Obviously, unlike employees, automated machines do not require breaks or off-duty hours, and require proper maintenance to minimize downtime. Robots are inherently consistent because they can be programmed to weld in specific ways for specific products. Automation in this application has the potential to further increase production with consistently high quality.
Rotating Type Welding Positioner
Spin welding positioner improves safety
China welding positioner can greatly improve the safety of workers in the production workshop, especially when placing large objects for welding. Past assembly and part positioning practices can be very dangerous, involving the use of forklifts, cranes, and chains. The machine is not specifically used for the task of rotating weldment components, and sometimes it can cause damage to the machine or cause the weldment to fall. If the machine is damaged, it may not only cause the downtime of the welding project but also cause the downtime of other areas of the facility that need the equipment to operate. On the other hand, spin welding positioners are special tools specially designed for repositioning weldments. If used correctly, they will not fail.
Another advantage of using a spin welding positioner is that you can reach high welding points on large components without using scaffolds, ladders, or elevators, without touching the floor. There is no need for workers to climb high places, the risk of accidents is reduced, and worker fatigue is reduced, which will make workers healthier in the long run. In addition, many companies report that when using spin welding positioners, OSHA reportable accidents are reduced on average because employees are placed in fewer hazardous locations to reach the welding point. Another danger when using older positioning methods is that many experienced employees know the best method for positioning assemblies, and this knowledge is not always passed on when they retire or leave the company. This leads to inexperienced employees performing dangerous tasks.
Spin welding position improves the quality
When using the spin welding positioner, the welding quality will be improved because the welding position can always be moved to the ideal position, so as to achieve the best and easiest work. Better ergonomics can bring better quality and repeatability, and workers can adjust the angle and height of the welding position. Workers will no longer need to reach out to weld or reduce visibility while working. Better weld visibility also makes it easier for workers to see if any welds are missing.
For any facility that welds a large number of products (especially large size products), the spin welding positioner is beyond doubt. Improved safety, reduced processing time, improved quality, and reduced worker fatigue are all beneficial to the company and will help companies produce more products using the same resources.
Robotics-enabled automated welding can provide large gains in productivity, profitability, precision, and repeatability - in the right applications. Manual welding has its merits, but the benefits of automated welding systems are increasingly compelling for many assemblies. However, many assemblers are implementing automated welding systems to increase quality, productivity, profitability, precision, and repeatability.
Welding automation can be broken down into two basic categories: semiautomatic and fully automatic. In semiautomatic welding, an operator manually loads the parts into the welding fixture. A robotic weld controller then keeps the welding process, motion of the torch, and stillness of the parts to robotically-optimized preset parameters that ensure quality and efficiency. After the weld is completed, the operator removes the completed assembly and the process begins again.
In fully automatic welding, a custom robotic system, or series of interconnected robotic machines, loads the workpiece, indexes the part or torch into position, accomplishes the weld, monitors the quality of the joint and unloads the finished product. Additional "part in place" and final product quality checks may also be designed into the machine if necessary. Depending on the operation, a robotic system operator may still be necessary for oversight, but the level of autonomy significantly reduces the margin for human error.
Robotics-enabled automated welding systems offer four main advantages: improved weld quality, increased output, decreased scrap and decreased variable labor costs.
If you want to learn more, please visit our website Auto Welding Positioner.
Weld quality consists of two factors: weld integrity and repeatability. Robotics-enabled automated welding systems ensure weld integrity through electronic weld process controllers. Combining mechanized torch and part motions with electronic recall of welding parameters results in a higher quality weld than can be accomplished manually. This offers instantaneous quality control. Furthermore, because a weld is made only once, defects are readily visible and detectable. Humans tend to "smooth over" a mistake with the torch, hiding lack of penetration or a possibly flawed weld. In some cases, leak testing and vision systems can be integrated into fully automated systems to provide additional quality control.
Repeatability is a function of the quality of the weld process controller and of the engineering of the machine motions. Mechanized welding provides repeatable input parameters for more repeatable output. Assuming the controller is functioning properly, the question becomes: Can the mechanisms of the machine position the parts or the torch within the specified tolerances for welding? The answer to this question will attest to the quality of the system purchased.
Semiautomatic and fully automatic systems increase output by eliminating the human factor from the welding process. Production weld speeds are set at a percentage of maximum by the machine, not by an operator. With minimal setup time and higher weld speeds, a mechanized welding system can easily outpace a skilled manual welder.
Automating the torch or part motions, and part placement, reduces the possibility of human error. A weld takes place only when all requirements are satisfied. With manual welding, reject welds often increase when welders become fatigued. Depending on the value of the parts when they arrive at the welding station, the cost savings in scrap alone may justify the purchase of an automated welding system. Automation should also be considered when assemblers need to minimize the risk of shipping a bad part to a customer.
Reliance on human welders can dramatically increase a manufacturer’s labor costs. When planning for labor costs, manufacturers must consider the time that welders spend producing assemblies.
Typically, a semiautomatic system has at least 2x the output of a skilled welder. A fully automatic system can be built with twin welding positioners on an automated shuttle. Such a system can load and unload parts at one station while welding occurs at the other. In this way, a fully automatic system can run at four times the pace of semiautomatic system, or eight times faster than the pace of a skilled welder.
Lost opportunity costs are also significant. If a skilled welder fails to report to work, the company’s variable costs skyrocket. Eight hours of production time is lost. Availability of skilled labor for manual welding may also pose a challenge. Conversely, general machine operators are more readily available and more affordable than skilled labor.
Despite all the benefits, welding system automation is accompanied by some drawbacks. Although the drawbacks can be controlled, they should be recognized from the onset of an automated welding project.
Robotics-enabled automated welding systems require a higher initial investment than manual systems. A modern manual welding power supply costs less than $5,000; semiautomatic systems often start around $30,000. Companies considering fully automated welding systems should budget $175,000 to $250,000 for a turnkey system.
When shifting from labor-intensive to capital-intensive processes, companies must adopt and rigorously follow preventive maintenance programs. While the gains in productivity, profitability, precision, and repeatability can be outstanding, an effective preventive maintenance program must be followed to minimize the risk of costly downtime.
However, what if I told you there was a way to avoid all of this, and still automate? With Formic's RaaS model, you pay nothing upfront for the system, you never have to worry about maintenance, and you get 24/7 support. All for one low monthly rate that’s almost always cheaper than the labor equivalent, comes with a much higher throughput and lower rework rate.
Find out which robotic welding is right for you
Before investing large sums in automation, assemblers should consider the product life cycle. Most products follow a predictable pattern of introduction, growth, maturity and decline. Assemblers would be ill-advised to sink cash into automating the assembly of an eight-track tape player. On the other hand, the demand for airbag elements and automotive emission sensors will probably remain strong for years.
With quality and productivity as buzzwords, and customers demanding superior products, implementing an automated welding system may determine whether a company remains competitive. To avoid pitfalls along the way, assemblers need to establish a strategy and follow it closely, and research how to get started with robotic automated welding.
First, assemblers should determine the exact objectives of the project. What specifically needs to be improved, accelerated or changed through automated welding? The following questions can help assemblers sort this out:
Once assemblers have answered these questions, the next step is to thoroughly research automation suppliers. Fromic helps answer these questions, and lends you automation experts to guide you through your welding automation process.
Automating with Formic, the only question manufacturers need to ask themselves is: what repetitive manual tasks can be automated in my facility right now?
If you are looking for more details, kindly visit Automatic Welding Positioner Factory.