Welding Robots

Phoenix offers cost-effective, turnkey solutions for welding robots and complete robotic welding systems for MIG, TIG, and robotic arc welding. We can also design customised robotic welding cells tailored to your specific requirements.

Looking for a welding robot?

At Phoenix, our extensive knowledge of major robot manufacturers, such as KUKA, ABB, FANUC, and Kawasaki, enables us to identify the ideal brand for your welding needs. We offer the quickest and most efficient options available in the market. Our extensive experience with robotic welding systems encompasses various types of robotic welding cells.

Why Contacting an Integrator for Robotic Welding is Crucial

Importance of Integrators for Robotic Welding

When it comes to robotic welding, partnering with a qualified integrator can be the key to success. They bring a level of expertise, experience, and ongoing support that can ensure the best possible outcome for your project. Here are just a few reasons why it’s crucial to work with an integrator:

Support for Optimization and Maintenance

Robotic welding systems need regular maintenance for optimal performance and durability. An integrator can guide and provide resources for continuous equipment optimization and prevent downtime. Choose a skilled integrator for maintenance and software updates.

Experience Implementing Complex Systems

Integrating a robotic welding system into an existing production line or facility can be a complex endeavor. A competent integrator brings broad experience and expertise to the table, guaranteeing a smooth implementation process and reducing potential downtime or disruptions.

Expertise in Technology and Applications

A competent integrator possesses a comprehensive understanding of the latest technologies and their practical applications in your distinct project. Additionally, they evaluate your requirements and recommend the appropriate solution for your circumstance, ensuring maximum efficiency and performance.

Robotic welding work cell with multiple processes

A robotic welding work cell with multiple processes typically involves a setup where a robotic arm or arms perform various welding tasks within a defined area. These processes could include:

robotic welding

MIG (Metal Inert Gas) Welding

This process uses a wire electrode that is fed through a welding gun, along with a shielding gas, typically argon or a mixture of argon and carbon dioxide. MIG welding is known for its versatility and is often used for welding mild steel, stainless steel, and aluminum.

TIG welding uses a non-consumable tungsten electrode to produce the weld. A separate filler rod may be added to the weld pool if necessary. TIG welding offers precise control over the welding process and is commonly used for welding thin materials, as well as for welding metals like titanium and magnesium.

Spot welding involves the use of electrodes to apply pressure and heat to two or more metal sheets to form a weld at localized points. It’s frequently used in automotive manufacturing and sheet metal fabrication for joining thin materials together.

Similar to spot welding, projection welding involves applying pressure and heat to a localized area, but in this case, the materials being joined have small projections or bumps that concentrate the heat and pressure, resulting in a stronger weld.

This encompasses various welding processes (like MIG and TIG) where an electric arc is used to melt and fuse metal together. Robotic arms equipped with welding torches are programmed to perform precise welds on workpieces.

Plasma welding uses a plasma arc, formed by passing an inert gas through a constricted orifice and then through an electric arc. It’s often used for welding thin materials at high speeds with minimal distortion.

Main Elements of the Robotic Welding Systems

An arc robotic welding system typically consists of several components working together to perform welding tasks efficiently and accurately. If these concepts are unfamiliar to you, our company can guide you through the entire process. Here are the main components:

The robot arm carries out the welding operation using joints and end-effectors (like welding torches) to move precisely and reach any point within the work envelope.

This device provides the electrical power necessary to create the welding arc. It regulates parameters such as voltage, current, and waveform to ensure proper weld penetration and quality.

The welding torch or gun is attached to the end of the robot arm and is responsible for delivering the welding electrode to the workpiece. It also provides shielding gas (in processes like MIG and TIG welding) to protect the weld pool from atmospheric contamination.

In MIG welding, a wire feeder supplies welding wire to the torch at a controlled rate for seamless welding.

The welding controller coordinates robot arm movements, controls welding parameters, and ensures precise synchronization between the welding process and robot motion.

Sensors detect weld quality, including seam tracking, vision systems for weld inspection, and temperature monitoring.

Safety measures are important in welding to prevent accidents. This may include fencing, light curtains, and emergency stop buttons.

Use welding fixture to position workpieces during welding. The fixture can adjust the workpiece to aid robot access and achieve high-quality welds.

Operators can easily program the robot’s movements, welding parameters, and settings using a pendant, touchscreen panel, or computer software.

robotic welding systems

By integrating these components effectively, arc welding robots can perform a wide range of welding tasks with high precision, speed, and repeatability, improving productivity and quality in manufacturing processes.

Key Elements That Make Up the Majority of a Robotic Welding Cell

Choose the correct robotic welding cell by evaluating the crucial elements listed below. Additionally, assess wire feeders, positioners, fixtures, and safety features according to your project’s requirements.

Consider payload, range, torch weight, and turntable axis when investing in robotic welding.

For precise welding, use welding jigs to guide the cuts, support the workpiece, and position everything correctly. Fixture jigs are essential when working with multiple parts. Welding clamps hold materials in place during welding. Therefore, use these tools to ensure accurate and successful welding projects.

A commonly used component in robotic applications is a part presentation turntable with two positions – one for the operator and one for the robot. Controlled by a simple motor mechanism and output signal, the turntable provides reliable and precise handling of manufactured parts. See more information below.

We install advanced welding components, including a torch, weld controller, and signal processor, all supervised by a central control unit. Additionally, we include a tip cleaner to maintain peak system performance. Our setup guarantees precise, superior, and effective welding, showcasing our expertise and skill.

To ensure a secure working environment, it is important to guard the cell while the robot operates. Two-channel safety systems are integrated into the equipment to provide protection against welding glare and reinforce safety standards in the workspace.

Robotic company uk
Robot arms used in robotic welding systems.

Two-Position Welding Turntable

A welding turntable is a valuable tool for welding tasks. It allows for consistent and precise welds by rotating the workpiece to optimal angles. A two-position turntable provides extra flexibility, saving time and effort by eliminating manual repositioning and increasing productivity.

It is common for installations to feature some form of two-position turntable. Additionally, this allows for completed parts to be removed and new parts to be loaded while the robot is welding the previously loaded parts.

It may also be necessary to reorient parts during the welding process to enable better access to the torch or to maintain a horizontal weld path. In the case of this type of workpiece presentation, there will be two stations: one for the operator to load and unload and another for the robot to carry out the welding operations. However, the rotational axis, in this case, will be part of the robot’s movement.

Moreover, two or three additional axes will also be provided for each station, allowing the robot to rotate the part both horizontally and vertically.

ABB Welding Robots
Examples of Robotic Welding Systems using turntables

Robotic Welding Systems

robotic welding cells
Robotic Welding Systems with Control Panel

Electrical Control Panel Robot

Companies should consider adding a control panel to their robotic welding cell to ensure versatility and safety of the robot cell.  The robot cell safety panel with cell control push buttons should be installed to fully control the cell, and the panel should be electrically connected to the robot controller. In addition, the panel must also include safety relays for the two safety circuits for both the robot and the positioner.

One circuit is for the Estops, which stops the robot in all modes, while another circuit is for cell access. This circuit will stop the robot and positioner simultaneously when the access door to the cell is opened and the robot is in Auto mode. If you need full robot integration, do not worry because we can help you find a suitable robot and the appropriate control panel. 

Advantages of Welding Robots

As manufacturing processes evolve, industrial robots are becoming increasingly prevalent in the field of welding. While welding was once a manual task, the use of six-axis robotic welding allows for numerous advantages. Welding conditions can be difficult for human workers, but robots aren’t affected by welding flash, heat, or fumes. Moreover, robotic arms can operate around the clock, 365 days a year when necessary.

Furthermore, robots operate with the same efficiency every time as their programming is repeatable and consistent, resulting in the same, high-quality welds every time.

robotic welding cells
KUKA Welding Robot - ARC welding robot
Specialising In

Phoenix offers a variety of system integration support services in our portfolio, catering to all stages of any robotic integration project. Click below to learn more about the most common robotic cells.

Turnkey Industrial Robot Solutions

Phoenix integrates and installs complete robotic milling solutions from initial design and consultation to manufacture. We also offer robot trainingrobot programming, robot simulation, commissioning, and technical support. Whether you decide to configure your complete milling robot cell around a new or reconditioned robot, we can assist you. For more information For more see our article Robotic Integrator in Manufacturing.