Welding Manipulator – Weld-Fab Automation

Welding Manipulator ' The Comprehensive FAQ Guide

In the market today, there are a ton of welding manipulators to choose from. But, how do you find the best one for your business or for your projects?

Contact us to discuss your requirements of welding manipulator machine. Our experienced sales team can help you identify the options that best suit your needs.

Today's guide will be focusing on just that! As a matter of fact, we will help and assist you in understanding what welding manipulators are. Furthermore, you'll also be an expert when it comes to choosing the welding manipulator for the job!

At the end of this guide, you'll not only be an expert with welding manipulators, you will also learn where you can get the best ones in the market!

What is a Welding Manipulator?

A welding manipulator is a machine or a device that you can use to make welding easier.

Sample of what a welding manipulator looks like

The primary function of a weld manipulator is to move the weld head to the workpiece in such a manner that it's closer and easier to reach.

One good reason why many welders choose to use welding manipulators is because of the fact that it can reach places, spots, and even heights that a regular welder might find difficult.

NOTE: In using a welding manipulator, it's always better if you have a welding positioner to give additional aid to your projects.

How Does a Welding Manipulator Work?

In case you're starting to question if it involves a robotic arm 100% of the time, or if you need to manually move it, don't fret ' we got you.

Image of a worker toggling or working on a welding manipulator

Basically, a welding manipulator sets a welding head in motion in order to reach spots, heights, and places on the workpiece.

It can be a manual welding manipulator where you would have to position the device to its rightful area, and it can be automatic and pre-programmed.

You can think of how it works easily ' think of a welding head that has an extended length. Thanks to this length, even if the project requires you to weld a 20-ft. vessel, you don't have to risk climbing up to that height to weld what's necessary.

That's the general idea of how welding manipulators work

What Are the Parts of a Welding Manipulator?

Ideally, different versions and kinds of welding manipulators have different parts. However, there are 'primary' parts that are common across all types and kinds of manipulators.

Image of a welding manipulator where the parts are highlighted

For instance, if you remove one of its primary components, the manipulator wouldn't properly function.  

Some of these primary parts include, but are not limited to:

• Welding bracket or support
• Control box (with motors)
• Welding gun support
• Welding head
• Pre-heat system

Without any of these, you wouldn't be able to call a machine a welding manipulator.

What Are the Different Types of Welding Manipulators?

While the market is filled with a lot of welding manipulators, there are three (3) considered the most common and the most purchased due to the functionality and the usage that they hold.

Sample image of a column & boom weld manipulator

The most common types of welding manipulators include:

Column & Boom Welders

Column & boom welders are welding manipulators that you usually use for welding structural beams, as well as other kinds and types of structures that are big and large in size.

It's called column & boom because it's comprised of a column (vertical metal), and a boom (horizontal metal). The two (2) go and function together; the column is what you can thank for the locomotion flexibility that the boom can give you.

A column & boom weld manipulator is a machine you can use to automate welding in such a fashion that the welding head is the one moved and adjusted.

Rotary Welding Positioners

A rotary welding positioner is a type of a device or a machine that you can use to help you accurately position the workpiece.

Unlike column & boom, rotary welding positioners reposition and manipulate the workpiece, instead of the weld head.

Welding Rollers

Last but definitely not least are welding rollers.

They're probably the least common type of welding manipulator in the market, but many business sectors and industries use this, too.

The idea behind weld rollers is for the welder to avoid slipping and inaccuracy when it comes to welding cylindrical objects and workpieces.

One good example is when a welder needs to weld a tank. It's going to be hard to use a welding positioner for it, especially if it's more than 50 kg ' and that's where the importance of welding rollers come in.

These are three (3) of the most common types of welding manipulators out in the market. Don't be confused, there are others ' these are only the favorites and the most used.

Can You Buy a Used Welding Manipulator?

Yes, there's not a written rule saying that you should 'never' buy a used manipulator.

As a matter of fact, buying a used welding manipulator holds too few benefits and advantages. For one, they're going to be much cheaper and more affordable than a brand new one.

Another benefit of purchasing a used weld manipulator is that you already know that the product is working ' you don't need to test it out.

Upon purchasing, though, it will be in your responsibility to see if the manipulator is still in its good condition. It will be up to you to determine this.

Welding Manipulators vs. Welding Positioners

Many people ask ' are welding manipulators and welding positioners the same?

Sample image of what a weld positioner looks like

Going back to the types of weld manipulators above, there's one named 'rotary welding positioners,' and it's technically the same.

They are two (2) different machines, and while both of them carry the same goal ' they don't function in the same way.

In welding manipulators, we talked about how it moves and sets in motion the weld head. On the opposite end of the rope, a welding positioner is a type of auxiliary machine that moves and positions the workpiece.

Don't be confused as to which is which; in fact, you can use both of them to complement each other!

What Specs Should You Look For in Welding Manipulators?

What do you look for in a welding manipulator? Are you sure that you're choosing them based on how you need them? Or just based off of what others are looking for too?

When it comes to the specs or the specifications of weld manipulators, you need to make sure that you're looking for the things that 'you' or 'your business needs.'

To help you with it further, here are some of the most important specifications.

Load Capacity

Load capacity refers to the maximum amount of load or stress that the manipulator is capable of withstanding without it underperforming.

Ideally, it's the capacity of your manipulator to carry and to work on a particular material in terms of weight.

Column Stroke

The column stroke refers to the maximum distance or stroke in which the column is capable of moving.

Generally, the usual column stroke of welding manipulators lie around 55 to 65 inches.

Boom Stroke

Akin to the column stroke, the boom stroke is the distance that the boom is able to travel; and to give you the most general idea of the length of the boom stroke, it sits at about 39 to 50 inches.

Equipment Mass

This is the total weight of the welding manipulator.

NOTE: In checking the equipment mass, be sure to know if the attachments are included. Some manufacturers don't include the attachments ' this can result to improper weight adjustments for shipping, etc.

Power Requirement

The power requirement is what the machine needs in order for it to operate.

Unlike other specifications, the power requirement will depend on the type of motor used, as well as the functionality of the weld manipulator.

It will vary from one manufacturer to another.

Travel Car Speed

A travel car is a component or a part of a welding manipulator that can perform long seam welding.

Therefore, travel car speed is the rate in which the travel car can go from one point to another.

These are some of the most important specifications to note in purchasing a welding manipulator. To put emphasis on it ' it's not all of them. There are far more specifications ' they're just what a wide variety of clients and customers look for often.

Benefits You Can Get in Using Welding Manipulators?

We all know that automated welding is being seen as one of the most effective solutions to the worst welding problems we grew out of.

Highly efficient results of welding in using weld manipulators

Even if that's the case, a lot of people still overlook the advantages of using weld manipulators.

In fact, here are some of the most notable benefits of using a welding manipulator:

Promotes a Safer Working Environment

The first thing to understand is that a welding manipulator promises a safer working environment.

With a welding manipulator, your welder wouldn't be anymore required to be side-by-side with the 10-ton workpiece.

The welder can simply go back and forth to see if the program for a particular project is done right and accurately.

Gives You Faster Production Rate

What do we need machines for other than the fact that they can eliminate human intervention? ' Speed.

With a welding manipulator, the amount and the volume of projects you can complete is truly unimaginable.

Several welders reported that they were able to finish a project at less than half the time when they were manually doing it.

Promises Precision and Accuracy in the Projects

Automated welding is not just existent to ensure that your projects will be done and accomplished fast ' but also to make sure that the consistency and the quality of the weld is there.

Yes, human welders have the consciousness of a human, and therefore, can easily adjust. However, automatic welding manipulators or those that you can program are accurate and precise to what you have programmed them to do.

There's going to be little room for errors, and that's a guarantee.

Promotes More Mobility and Flexibility

And last but definitely not least is that it can give your welders mobility and flexibility.

Let's say you have a welder that is not so tall ' how would he be able to reach an 8-ft. weld? That's easy if we consider using a welding manipulator.

No matter how high the weld needs to be, and no matter how stiff the welder is, a welding manipulator will be more than enough to do the trick.

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Welding Processes You Can Use With Welding Manipulators

Would all types of welding be compatible in using a welding manipulator? Apparently, yes ' but not all might be effective.

There are several welding procedures that might not find the success with weld manipulators. But, among those that have been proven and tested to work effectively include:

• MIG or Metal Inert Gas Welding (GMAW)
• TIG or Tungsten Inert Gas Welding (GTAW)
• Stick Welding
• Laser Welding
• Plasma Welding
• Submerged Arc Welding

What is a Pipe Welding Manipulator?

A pipe welding manipulator is a pretty self-explanatory machine.

Image of a pipe welding manipulator in action

It is a welding manipulator that you'd have to use if you are to work on pipes, tanks, vessels, and other rounded and cylindrical workpieces.

They're specialized to have a good grasp of the workpiece even if it doesn't have a rough edge.

Are There Portable Welding Manipulators in the Market?

Yes, you can purchase portable welding manipulators, and there are lots of them in the market.

Do note, though, that although they're portable, they might not be able to give you the exact results you're looking for.

As a matter of fact, you might not be able to use them for medium-to-heavy-duty applications.

What is a Seam Welder?

You can identify seam welding to be the welding of two (2) materials through electrical resistance heat generation.

Seam welding machine

The idea behind it, so you could understand it easier, is the word 'seam.'

A seam welder, therefore, is a device or a machine that you can use to initiate the fusing or two (2) different materials down a never-ending seam.

Renting vs. Buying Welding Manipulators: Which One is For You?

The golden question that everyone wants to know the answer to. Would it be better to rent a welding manipulator or to purchase them outright?

This question is actually relative and the answer to this will vary depending on your business needs, your budget, and how you would use them.

Let's take a look at the pros and cons of each.

Pros of Renting Welding Manipulators

Here are some of the benefits and advantages of renting out welding manipulators:

• Less stress about the maintenance of the machine
• You don't need to shell out a huge amount of money to start
• Perfect for temporary and light-to-moderate use
• Wide variety of options in choosing which to rent

Cons of Renting Welding Manipulators

When it comes to the drawbacks and the cons of it, they are as follows:

• You don't have total decision over the machine
• There are limits as to how you can use them
• You have to make sure it doesn't wear off while you're in a lease
• Extra charges may apply if the renting company deems that it wore out during your use

That's what we have if you plan on renting welding manipulators. Now, let's look at buying or purchasing them outright.

Pros of Buying Welding Manipulators

• You'll have total control over the machine, how to use it, where to place it, etc.
• You will be able to study it thoroughly as you can dismantle and re-assemble it
• Your workers can perform a wider array of tasks with it compared to renting

Cons of Buying Welding Manipulators

Here are some of the disadvantages of purchasing welding manipulators vs. renting it out.

• It's typically expensive ' you'll need a large sum of money for it
• The delivery could take about 7 to 12 days ' even up to 3 weeks
• Might require a bit of experience for continuous automated welding

Those are the points that differentiate renting a welding manipulator from purchasing one.

How to Choose the Best Welding Manipulator For Your Needs?

Choosing a welding manipulator isn't a walk in the park. As a matter of fact, you can consider this to be the most important aspect of your search.

There are lots of different varieties of welding manipulators you can choose from

All welding manipulators are different in terms of type, size, weight, as well as the features and functionalities.

And, in order for you to get the most out of your purchase, you have to remember the following tips so that you get the best type of welding manipulator for your needs.

Consider Your Business

The first thing we want to talk about is the business that you have. More often than not, businesses forget that they're purchasing welding manipulators for their projects; they tend to overlook it, which makes them purchase the wrong or the incorrect manipulator.

But, if you consider your business, several scenarios will play in your head. You'll try to remember the processes and the projects you need to do, the materials you need to weld, etc.

Consider the Control System

Akin to the features and functionalities of the welding manipulator of your choice, the control system would also be different from one manipulator to another.

What this basically means is that not all welding manipulators would have the same ways of control. There would be manipulators that have a digital control system, a manual control system, etc.

Consider the Ease of Use

Try to picture yourself operating the machine ' would you be comfortable in doing that? Would the operation of the machine be convenient to your capabilities?

You might not be the one operating it, but try to put your shoes on the welders and the operators.

Check and see if the head adjustment is easy enough to operate, look at the slides and the movement adjustments if it fits your knowledge, and the like.

Consider Upgrading in the Future

When you are purchasing a welding manipulator, you need to accept the fact that you'll be using it for a long time.

As a matter of fact, you might even need to upgrade to a new one if the moment is right. So, in choosing a manipulator, make sure that you consider the price and the value of it if you are going to upgrade it.

These are a couple of the most important things that you need to consider in choosing which welding manipulator to buy.

Where Can You Get Good Quality Welding Manipulators?

Finding the best welding manipulator in the market is not easy, but if you work with us here at Weld Fab, we can definitely attend to all of what you need.

For years, we've done nothing but provide excellent quality welding manipulators. Over time, we have successfully developed and streamlined our business processes, resulting to higher and better quality of products in our arsenal.

So, if you ever find yourself in need of a longitudinal seam welding manipulator, column and boom manipulator (TIG, SAW, and MIG), or even a circular seam welding manipulator, you can trust us!

Why Trust Weld Fab's Welding Manipulators?

Weld Fab is just one of the thousands of Chinese weld manipulator manufacturing companies. But, that doesn't mean that we offer the same quality and the same type of products as them.

As a matter of fact, we're known in the industry for we have provided numerous clients with the exact welding manipulators their businesses needed.

Thanks to the continuous development of our Research & Development (R&D) team, we're able to help you even further by offering custom welding manipulators for you!

• We offer one (1) year worth of warranty on all our products
• Under our employ are highly-skilled and experienced electrical experts, welders, and engineers
• Weld Fab can give you the guarantee and the assurance of a smooth pre and after-sales services
• We can offer you a free tour of our manufacturing plant so you can see what type of business we are

Wherever you are in the world, you can put your trust on Weld Fab! Thousands of businesses and companies like you from all across the globe rely on us and our production ' you can, too!

Weld Fab is skilled and determined to provide tens of tons of weld manipulator products per year!

Don't worry about where you can get your next batch of weld manipulators ' contact us and we'll supply you with a free estimate!

Be Updated!

As the best weld manipulator supplier in China, our product line is always updating. We're always on the run for the best, the newest, and the most updated products a majority of businesses need.

Reach out to us and learn more about how Weld Fab will be the best company you can work with!

Used on production lines for decades, robotic welding is a tried and tested technology that can reduce costs without compromising quality. Despite the advantages, many businesses believe that robotic welding systems are expensive and only used in sprawling automobile factories.

In reality, technological advances now make automated systems affordable for small and medium enterprises and supplement traditional fabrication techniques perfectly. Automated Welding using Industrial Robots can benefit manufacturers of any size, making production lines more efficient and resilient to workforce highs and lows.  

What is Robotic Welding?

The US automobile industry embraced robotic welding in the s, and the technology soon spread to other industries. Between and , companies installed over 150,000 industrial welding robots, and the market for welding automation is predicted to grow at a compound annual growth rate (CAGR) of 8.91% between and . With many vendors exploring new technologies, robotic welding will continue to thrive.

Welding Robot Layout

Some robot arc welders consist of a mechanical unit that can manipulate the welding gun and work on a static part, while others move the part and weld with a static gun. A command unit using pre-programmed commands directs the robot's actions, sometimes using sensors to provide machine vision and extra precision. Robotic welding is a very versatile solution for sheet metal or complex components.

Robotic welding units can use a number of welding techniques:

• Arc welding
• Gas welding (MIG/GMAW and TIG/GTAW)
• Laser welding
• Resistance spot welding
• Plasma welding

Alongside the welding apparatus, robots often include ancillary equipment such as a wire cutter, nozzle cleaner, and torch changer. Components enter the cell/work area and the robot completes the weld before the component moves to the next stage.

Movement

Robotic welding systems move in the three x, y, and z-axes using a rotational wrist. Articulated robots incorporate a lower arm and wrist providing three axes of movement each, allowing the welding torch to move in three dimensions.

A number of robots include manipulators that extend the range for working on large pieces and complex geometries, often aided by the additional of a seventh axis at the base. Synchronised control of the welding torch and manipulator maximises speed and accuracy.

Sensors

Some welding robots contain sensing technology and artificial intelligence, which measure the process and send data to the control system, offering a high degree of control. Sensors can ensure a number of parameters remain within acceptable limits, including:

• Voltage
• Current
• Wire feed
• Location and geometry of the work piece and weld
• Seam finders to monitor quality
• Collision sensing
• Video equipment to verify part position and clamping

Although robots require significant investment, the advantages make robotic welding worthwhile across a number of industries.

Advantages of Robotic Welding

Many small and medium enterprises perceive that robotic systems are expensive and difficult to use, but the latest technologies are affordable and simple to program and maintain. At a time when customers are increasingly price sensitive, yet demand higher quality and consistency, manufacturers must improve efficiency without affecting quality.

The main advantages of robotic welding include:

• Flexibility
• Increased Efficiency
• Quality
• Lower Costs

Flexibility

Modern welding robots are can perform single repetitive tasks or complete different tasks, even over the course of a single shift, by drawing upon a library of stored programs. This is particularly useful for businesses with smaller product runs or a large range of products.

Many robot arms support additional tools, and some hybrid processes blend automated and manual welding, especially for welds beyond the reach of humans. Custom robotic systems offer optimal configuration to maximise the use of space, while modular systems allow plants to adapt systems to match their unique needs.

Increased Efficiency

Whilst any individual weld takes the same amount of time regardless of whether it is a human or a robot, automated welders work at a greater efficiency than humans. By some accounts, robotic welders can achieve up to 85% efficiency, compared to around 20% for most welding professionals.  

The predictable cycle time makes scheduling easier and removes potential bottlenecks; giving a consistent throughput and helping manufacturers deliver components on time. Because robots weld cleanly and with high precision, there is less need for post-weld cleanup and dressing, saving time further down the production line.

Quality

Because weld speed, current, and other variables remain constant, robots deliver very high weld quality. For example, gas metal arc welding (GMAW) requires a very stable arc length and speed, alongside consistent torch angle and position. Welding robots offer tenths of a millimetre precision at a constant speed, often supported by vision systems that provide quality control.

Automated systems offer:

• High output
• High quality and repeatability
• High precision
• Weld accuracy
• Identical parts

Robots do not suffer fatigue or distraction, so weld quality is consistent and the lack of compromised welds supports customers with stringent quality requirements for critical systems.

Costs

Robotic welding can lower costs and deliver a return on investment in a number of ways. A robot's ability to position parts with high precision and use automated parameters creates fewer errors that require rework or outright rejection. Robots waste less gas, base metal, electricity, flux, and other consumables, which creates significant savings over time and ensures that work is less likely to stray over budget.

In addition, robots are tireless and can operate 24/7, and can lower labour costs significantly. Businesses will spend less on training programmes, suffer fewer occupational injuries, and can overcome any shortages in skilled labour. Instead of repurposed general robots, some vendors now provide specialised welding units that are less bulky and lower-priced, making the technology even more affordable for smaller businesses.

Programming and Communications

Welding robots are very complex machines but can be easily programmed by a Robotic Automation Specialist, with little ongoing support required. In contrast, welding takes years to learn, leading to skills shortages and the need for higher wages to attract staff.

A robotic process line can store many preset programs, allowing the same production line to store multiple programs for different products, requiring only a relatively simple change of tools on the robot's arm. This flexibility makes robotic systems perfect for one-off orders and lower volume producers. Robotic welding systems take advantage of modern communications networks that transmit high volumes of information for analysis and allow centralised control in near real time.

Despite the advantages, robotic welding systems can't replace all manual welding tasks because some components are too difficult for a robot to manipulate or access. Experienced welders can start a job straightaway, adapt to changes, and provide instant quality control. Robots usually take over repetitive tasks and free up skilled welders to concentrate on complex jobs.

Get expert support from our robotic welding specialists

While robotic systems are still a significant investment, the price has fallen sharply and the capabilities and flexibility of modern operating software makes welding robots a smart purchase for many Australian businesses. Robotic welding offers precision, quality, and consistency, while the reduced costs mean the technology increasingly makes business sense.

At Robycs Technology, our expertise will help you find the perfect automated welding system for your business, drawing upon expertise in ABB, KUKA, Universal Robots, FANUC, Mitsubishi and many other vendors.

We don't just help you choose the right robots: we work with you from the start and help you identify where automated welding will streamline production and help you reduce costs. If you want to take advantage of robotic welding, contact us.

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