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Collaborative robots are rapidly transforming manufacturing floors, and their impact on welding operations is significant. Once the exclusive domain of highly skilled human welders or specialised, caged industrial robots, the ability to automate welding tasks with flexible, easy-to-deploy cobots is opening up new possibilities for businesses of all sizes.

With the UK currently facing a significant shortage of skilled welders, the answer to the industry's challenges lies in advanced technologies and automation. But how exactly can cobots contribute to welding operations? 

Why Use a Collaborative Robot Over an Industrial Robot for Welding?  

When considering automation for welding, two main types of robots come to mind: traditional industrial robots and collaborative robots, or cobots. While both aim to improve efficiency, their fundamental design and operational philosophies differ significantly, especially in a world facing a shortage of skilled welders.

Unlike traditional welding robots, which operate autonomously within caged areas for safety, cobots are designed to work alongside humans in a shared workspace. They are engineered with sophisticated sensors and control systems, allowing safe, efficient interaction with human operators. This distinction is crucial, as traditional robots require a clear separation from human activities to ensure safety, whereas cobots are built for close interaction.

This collaborative nature makes cobots a game-changer, particularly for businesses grappling with the scarcity of skilled welders. An increasing number of companies are using welding cobots to automate processes, including high-mix, low-volume part runs. This strategic adoption frees up skilled welders to tackle more complex welding projects, optimising the use of valuable human expertise.

Cobots are remarkably easy to program and use, thanks to their intuitive control systems. They are also compact, offering the flexibility and scalability to handle new tasks in a matter of minutes. This is in stark contrast to traditional robots, which often require more specialised programming and dedicated setups.

In essence, cobots were developed to bridge the gap between full automation and manual labor, making automation more accessible for manufacturers of all sizes, particularly SMEs. Unlike traditional industrial robots, cobots offer lower upfront costs and increased flexibility, rapidly becoming a game-changer for companies looking to boost productivity and maintain high-quality welds. The significant advancements in cobot technology in recent years have cemented their position as a practical solution for automating welding processes, improving consistency, and enhancing overall productivity in the manufacturing sector.

Types of Welds Cobots Can Deliver

One of the most compelling advantages of integrating cobots into welding operations is their remarkable versatility in handling a wide array of welding techniques. This adaptability makes them invaluable tools across industries that demand different welding methods for various materials and products.

For those new to automaton, a cobot welding system typically consists of: 

• A collaborative robot arm that moves the welding torch along the programmed path. 
• A welding power source, providing the necessary electrical current for the welding process. 
• A welding torch, the tool that delivers the weld, connected to the power source.
• Programming flange, which simplified the setup and operation of the welding cobot. SmoothTool by Smooth Robotics allows operators to manually guide the cobot to define the welding path. 
• Teach pendants provide a user-friendly way for operators to program the cobot with simple, intuitive controls and touchscreen interfaces.

Their broad capabilities mean fabricators can leverage cobots to create specific weld programs for individual workpieces or parts. The ease of switching between different weld programs and workpieces allows for a consistent, repeatable, and semi-autonomous weld workflow, which dramatically boosts productivity. MIG/MAG welding is by far the most common application for collaborative robots, but they can undertake a range of weld, such as:

MIG/MAG welding: delivering speed, ease of automation, and versatility, cobots are primed to take on these welding tasks. Delivering consistent, repeatable welds across a range of materials, such as stainless steel, carbon steel, and aluminium, support long welds and complex geometries with minimal rework

TIG welding: the steady hand of a cobot delivers precision and clean, high-quality welds, ensuring a stable arc to prevent defects and deliver a flawless finish. When your welding applications involve challenging exotic materials or require meticulous attention to critical joints, TIG welding cobots offer a compelling advantage. 

Spot welding: while often associated with larger industrial robots, cobots are finding their niche in spot welding applications. Bringing new advantages to the table, cobots offer the flexibility to handle varied part geometries, reduce manual effort for operators, and significantly improve consistency in weld placement and pressure. 

Laser welding: the inherent accuracy and speed of laser welding are amplified when paired with collaborative robots, creating a true powerhouse for precision welding. This method, known for its minimal heat input and fine control over weld seams, is crucial in demanding fields such as aerospace, medical devices, and electronics. 

With their exceptional ease of programming and inherent adaptability, welding cobots are truly revolutionising welding applications across a diverse range of sectors, making advanced automation accessible and practical for a wider array of manufacturing needs. For SMEs, they are an indispensable tool for when absolute precision is a non-negotiable requirement.

The Future of Cobot Welding

CoboWeld, Cobots Online’s innovative range of welding cobots, delivers a strong solution to mitigate the welder shortage crisis and help businesses increase production. By taking on repetitive, strenuous, and precision-demanding tasks, CoboWeld allows human welders to focus on more complex and critical aspects of the welding process. Its user-friendly interface allows for quick learning and easy operation, effectively reducing the barrier to entry for new welders. Furthermore, the collaborative nature of CoboWeld fosters a more engaging and safer work environment.

From small workshops to large manufacturing plants, cobots are proving to be a highly effective and accessible solution for a wide range of welding applications, helping businesses improve efficiency, quality, and worker safety.

For a demonstration of our welding cobots, or to learn more about how you can transform your welding operations through automation, contact Cobots Online to discuss your requirements.