The Importance of Sensors in the Robotic Welding Application

We currently have a dynamic market that demands flexible manufacturing systems with higher quality, productivity, and lower costs. The welding industry is one of the processes that has managed to achieve the goals imposed by the market through developments and alternatives to maintain competitiveness in the market.

The most operational market where most industrial robots are adopted is the welding sector, with the highest demand in the automobile manufacturing industry, followed by the electrical and electronic industry.

Over time, welding systems required greater efficiency, where the process reflected greater efficiency, precision, and less cost. The alternative was to optimize them with industrial robots. As the market continues to be even more competitive, technologies and developments need to be improved.

The integration of sensors has made it possible for businesses to optimize their robotic welding processes.

The two most commonly used robotic welding processes for production purposes are metallic inert gas (MIG) welding and tungsten inert gas (TIG) welding. Different sensors have been designed to improve and solve some of the challenges that these welding processes present.

Why Investing in Sensors is Worth the Cost?

Giving a decisive answer to why investing in sensors is complicated since different considerations must be taken into accounts, such as the needs of the process, material, time, and type of sewing.

The sensors have provided welding processes with several alternatives. Some are low cost and limited in capacity, while others involve a significant investment and, in some cases, with a custom design, some with the benefit of cost savings.

New sensor technologies verify the activity and location and orientation of parts. They can also perform quality controls on the part to provide a positive impact on the system.

Types of Sensors Used in Robotic Welding

Here are the different types of sensors used in robotic welding.

Touch Sensors: Touch detection uses sensors that make electrical contact between the welding nozzle or electrode and a predetermined point on the part. The robot then stores the data to maintain a high level of precision during sewing. Its cost is low, and it’s best for the orientation of the pieces with simple joints and geometries.

Sewing Tracking with Arc Sensors

This means real-time tracking of the welding process by checking robot path changes, adaptive control, voltage settings, wire feed, travel speed. It is a low-cost sensor, better for application on pieces with long or curved seams or with variations.

2D and 3D Camera Sensors

Robotic vision systems can locate parts of any size, shape, or position. They react efficiently and quickly in the location of a point to be welded, avoiding inaccuracy errors in the seams.

2D and 3D camera sensors are best applied to parts with greater placement, variability, and demanding cycle times. Their cost is medium-high, and they improve the weld production in shorter cycle time, and with greater flexibility and precision.

Adding sensor technology could be the best solution for offering a high-quality weld.

If you’re looking for cost-effective and high-performing welding robots with built-in sensors, get in touch with Used Robots Trade. The company offers robotic welding systems online for sale, as well as robot mechanical parts for welding cells. They house a wide range of used and new robots from the top leaders in the robotics market, including KUKA, MITSUBISHI, FANUC, ABB, KAWASAKI, and others.

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