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 weld controller then keeps the welding process, motion of the torch, and stillness of the parts to preset parameters. After the weld is completed, the operator removes the completed assembly and the process begins again.

In fully automatic welding, a custom machine, or series of 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 machine operator maybe necessary.

Advantage

Automated welding systems offer four main advantages: improved weld quality, increased output, decrease scrap and reduce labor costs.

1.Weld quality consists of two factors: weld integrity and repeatability. Automated welding systems ensure weld integrity through electronic weld process controllers. It results in a higher quality weld than can be accomplished manually.

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.

2.Semiautomatic and fully automatic systems increase output by eliminating the human factor from the welding process. With minimal setup time and higher weld speeds, a mechanized welding system can easily outpace a skilled manual welder.

3.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.

4.Typically, a semiautomatic system has at least twice the output of a skilled welder. A fully automatic system can be built with twin welding positioners on an automated shuttle. Also, general machine operators are more readily available and more affordable than skilled labor.

Disadvantage

1.Despite all the benefits, welding system automation is accompanied by some drawbacks.

Automated welding systems require a higher initial investment and power supply cost than manual systems.

2.Flexibility is also an issue.  While a manual welder can easily move from one part to the next, specialized welding equipment and systems can only satisfy a dedicated niche in the manufacturing process.

Welding is arguably the most complex manufacturing process. Manual welding is still the best process for many assemblies. However, many assemblers are implementing automated welding systems to increase quality, productivity and profitability.

Automatic welding has huge advantages over manual welding. It can be widely used in the process of railing accessories’ production, greatly improve production efficiency and product quality, and reduce manufacturing costs. With the mechanization and automatization of production, automatic welding will inevitably become the growing trend.  In the long run, automatic welding is a better choice.