The answer could actually be neither.
Robotic welding technology isn’t that new anymore. It may have dominated automotive manufacturing in the early 80s, but auto manufacturers couldn’t gatekeep the technology for long. Nowadays, advanced robotic welding cells are used in small and larger fabrication shops across the globe while a newer, more agile technology begins to make waves. And even the most advanced technologies can sometimes not compete with the precision, agility, and reflexes of highly skilled and passionate Hobart-trained welders. In the ever-changing world of manufacturing technology, keeping up with the latest advancements is a feat in and of itself, one many manufacturers don’t have the time or resources for.
As a result, they tend to lean towards either manual or robotic welding, but maybe a mix of both is what you really need. At Raymath, we are embracing cutting-edge cobot welding technology that utilizes the latest cobot technology to work in tandem with our welding professionals, blending state-of-the-art capabilities with advanced human expertise. Unless you’re elbow-deep in the welding industry already, the scope of welding methods and technologies can be difficult to navigate and determine which is right for your manufacturing projects. Now you can utilize both robotic and manual welding on the same part.
Defining the Types of Welding Technologies
Welding technology goes beyond MIG, TIG, and ARC, enveloping a range of automated and manual capabilities offering unique advantages, disadvantages, and best use cases. Here at Raymath, located a stone’s throw from America’s most respected welding school, the Hobart Institute of Welding Technology, we have the privilege of employing some of the industry’s best Hobart-trained welders specializing in manual, robotic, and cobot welding technologies. We leverage this combined knowledge and expertise to develop the most cost-effective welding processes regardless of complexity or production volume requirements.
Manual Welding
Manual welding is an art form, one that takes years of practice to learn, longer to master, and a lifelong commitment to continuous learning and improvement. Recent advances in material science alone demand additional expertise to reliably join innovative high-strength, low-weight alloys, prevent distortion in aluminum, and consistently achieve precision results in the growing complexity and shrinking tolerances of modern weldments.
The Good
Despite massive technological advances, manual welding is still vital to modern manufacturing. Skilled human welders are much more responsive and flexible than machinery. This allows them to rapidly adjust to different materials, weld types, fixturing, and unexpected issues in real-time. Computers, even the most advanced programs, still require reprogramming to adjust to new specifications. Manual welding experts, on the other hand, can quickly adapt to changing demands and are better equipped to handle highly complex joints.
The Not-So-Good
However, humans are not robots. They err, they get tired, they have bad days, and no two humans have the same experience or skill set. This can cause inconsistencies and poor-quality welds throughout production, resulting in costly rework and material waste. Inconsistencies become more apparent over longer production periods. Manual welding is also slower and more expensive labor-wise, making it cost-prohibitive for higher volume requirements. And that’s not taking into account the skilled labor shortage that much of the country is struggling with. Good, skilled, reliable workers are hard to come by and know their worth, making them a hot commodity with a hefty price tag.
The Best Use Cases
Manual welding is best reserved for manufacturing projects that demand flexibility, require extreme geometries, or have low-volume production requirements, such as prototypes, one-off projects, short runs, and high-mix/low-volume requirements. Manual welders are also best suited for component repair work and achieving high-quality results where real-time decision-making is required, such as with hard-to-access welds.
Robotic Welding
Robotic welding has come a long way since it first made its appearance spot welding car frames. Today, robotic welding combines advanced multi-axis capabilities with servo-driven positioners and cutting-edge vision and touch sensors, allowing this technology to expand into a wider range of applications and reach greater precision in more complex designs. With greater capacity and network connectivity, robotic welding can now require more advanced programming, which requires a specialized skill set.
The Good
Robotic welding, a harbinger of modern manufacturing, excels at tasks that human welders simply can’t reproduce with any long-term reliability, especially repetitive tasks that require constant results across higher-volume, longer-running production cycles. When paired with additional automated processes, such as material loading and unloading capabilities, robotic welding cells can operate at peak efficiency, under minimal direct supervision, day and night.
The Not-So-Good
Robotic welding cells are engineered to produce high-quality welded seams and joints following detailed programming that ensures precision and uniformity, rapidly meeting high-volume production requirements. While this makes them ideal for mass production, it’s not the most efficient method for lower volume requirements. Reprogramming these advanced machines is a time-consuming process, restricting their flexibility with longer changeover times.
The Best Use Cases
Manufacturing projects that require high-volume, repetitive welds are where robotic welding offers the most benefits. Once programmed, advanced welding capabilities will consistently produce thousands of high-quality welds that meet the strictest standards. Their ability to reliably produce tight-tolerance welds with minimal variability ensures proper fit and function from the first component to the last.
Cobot Welding
Cobot welding, or collaborative robotic welding, combines human expertise and agility with the superior consistency and speed of robotic capabilities and then bumps it up with Industry 4.0 technology. Cobot welders can work with human welders, utilizing the knowledge and skill of the manual welder with the repeatability and endurance of a robotic welder.
The Good
Cobot technology is designed for easy operation, quick programming, and intuitive interfaces. Combined with advanced sensors, cobots safely work in shared workspaces, allowing manual welding specialists to work alongside cobots to achieve complex results with reduced setup times. Between easier programming, increased connectivity, and advanced sensors, cobot welding enables quick adjustments and rapid changeover.
The Not-So-Good
Cobot technology is still relatively new and contains highly sensitive components that can become damaged in harsh environments or heavy-duty applications. These same technologies also work to safeguard human welders, resulting in slower production than robotic welding cells but more flexibility.
The Best Use Cases
Cobots are best deployed when you want the repeatability of a robot but the agility of a manual welder, usually a high-mix production, medium volume group of parts. Cobots are able to handle long seams, circular welds, and overhead positions with consistent quality, allowing human operators to focus on high-skill welds. Their advanced flexibility and ease of operation make them ideally suited for projects that require frequent changeovers.
Which to Choose: Manual, Cobot, or Robotic Welding?
Each technology excels under different conditions; however, the right one will drastically improve overall cost-effectiveness. Some complex fabrication projects might even benefit from hybrid approaches, utilizing robotic welding for high-volume components that become subassemblies with cobot welding and are installed by expert welders. Determining which welding method to use hinges on several project-specific factors, including:
- Production Volume and Mix
- Part Complexity and Geometry
- Tolerances and Fit-Up Variations
- Changeover Frequency
- Weld Quality and Traceability
Why Choose When Raymath Specializes in All Three?
Raymath has dedicated the better part of 25 years to adopting the newest technologies and advanced welding capabilities to provide our customers with the highest-quality weldments crafted by industry-leading experts. We can provide the best of all worlds, highly skilled manual welding where needed, industrial style robotic welding when needed and collaborative cobot welding when the product mix demands it. We leverage our extensive experience and comprehensive welding capabilities to develop customer-focused solutions to their welding needs. Whether you need rapid precision prototypes, have complex designs with high-mix components, or high-volume production requirements, we have the welding technology to ensure cost-effective manufacturing of high-quality precision components delivered when you need them.
Contact us today, and let’s work together to streamline your metal fabrication projects.
