The welding industry has a significant labor shortage. The American Welding Society estimates the US has 375,000 fewer welders than it needs to keep up with demand today.
Collaborative robots, known as welding cobots, can help to fill some of this gap, improving productivity and reducing costs. The effectiveness of cobots depends largely on their design, and electrical connectivity and safety are critical. Here’s a closer look at how welding cobots are transforming the industry and what factors design engineers and operations managers should consider when building or investing in them.
What are some examples of welding cobots?
Welding cobots are designed to be flexible and mobile so they can work alongside professional welders and easily be programmed or moved to different parts of the production floor. They can improve precision and safety for difficult welding projects. A few specific examples include:
Additive manufacturing
Additive manufacturing requires welding many parts together to produce three-dimensional products based on digital models. These parts may be small or have hard-to-reach angles that can be challenging for welders. Arc welding cobots can be especially helpful for these applications.
Automotive and aerospace manufacturing
Welding cobots are a good fit for manufacturing complex vehicles with hundreds of parts, such as cars or aircraft. They can weld hard-to-reach areas, including chassis, fuel tanks, and engine parts.
Metal fabrication
Any application that requires joining sheet metal or fabricating structural steel requires precise welding. Welding cobots are also useful in consumer electronics because they can weld small components such as brackets or casings.
Pipework and tank manufacturing
There is no margin of error when welding pipes or tanks for industries including oil and gas and defense. These applications need to be durable, leakproof and meet precise measurements, which can be challenging even for the most experienced welders.
Repetitive manufacturing processes
Many manufacturing processes include repetitive motions that can be tiring and frustrating, especially for highly trained welders whose skills could be better used in more specialized operations. These processes are ideal for welding cobots that can be programmed to complete certain tasks over and over.
What are the most important factors when designing welding cobots?
Conductivity
In welding, "conductivity" refers to a material's ability to conduct electrical current, meaning how well it allows electricity to flow through it; essentially, it's a measure of how easily heat can be generated in a material during the welding process, with higher conductivity allowing for better heat transfer and a more efficient weld.
Key points about conductivity in welding
Good conductivity is crucial for welding as it ensures enough heat is generated to melt the metal and create a proper fusion.
The type of metal being welded, the cleanliness of the surfaces, and the design of the welding circuit all impact conductivity.
Conductivity is the opposite of resistance, meaning a material with high conductivity has low electrical resistance.
If a material has low conductivity, it can lead to uneven heating, difficulty achieving a proper weld pool, and potential for weld defects. Metals like copper are often used in welding equipment due to their excellent electrical conductivity, which allows for efficient current flow.
Resistance to heat
Welding operations produce extreme heat, which can severely impact the performance of electronic connectors. The temperature of a TIG welding arc can exceed 10,000℉, for instance. This often requires engineers to opt for connectors that can withstand high temperatures without compromising performance. The Amerline 5105 MS Resilient circular connector series is designed with a protective finish to guard from harsh conditions and temperatures up to 257℉, making it an ideal choice for applications that involve extreme heat.
Ability to withstand corrosive chemicals
Welding creates gas byproducts, including ozone and nitrogen oxide, that can be toxic to people and corrosive to metals. The process also releases toxic fumes when metals coated with paints or primers are heated to high temperatures. Exposure to these corrosive chemicals can cause connectors to degrade over time. This makes it crucial to use highly durable electronic connectors that can withstand corrosion. The Sealconn-Hummel M40 Power connector series is especially well-suited for welding cobots and other applications. With its durable nickel-plated brass housing, it’s not only resilient but also easy to install. Its intermateability further ensures seamless repairs.
Compliance with industry safety regulations
The welding industry has specific and serious safety risks, including fires or explosions, burns, electric shock, or eye damage from welding arcs. Unexpected failure of a welding cobot or other welding equipment can be catastrophic. Manufacturing facilities with welding operations must meet advanced safety requirements, including OSHA and NIOSH regulations and standards set forth by the American National Standards Institute and American Welding Society. These standards specify safety practices for welding materials, processes and personal protective equipment, but they don’t necessarily address welding cobots. Cobots rely on electronic connectors regulated by national standards that include UL certification, which certifies connectors based on current rating, voltage, temperature tolerance and other factors. For companies in the European Union, connectors must comply with CE standards, while companies in other countries may refer to the International Electrotechnical Commission.
IP ratings are another important consideration, denoting the degree to which connectors are shielded from interfering objects, dust, and water.
Fujikura (formerly DDK) connectors offer safety compliance certifications and IP ratings.
The CE01 series connectors are UL approved (File No. E72124) and have an O-ring which conforms to IP67 standard when mated.
Ease of maintenance and repair
Welding cobots are highly engineered with many specialized components, which can make them costly to repair. The costs of those repairs goes beyond labor and materials. For high-volume manufacturers, even a few hours of downtime can cost tens of thousands of dollars in lost productivity. Electronic connectors that are designed to be intermateable and intermountable can reduce downtime and make repairs more cost-effective. Connectors that use quick bayonet coupling can also be connected and disconnected easily.
There are several connectors that meet this criteria, including the Amerline 5015 Commercial EFR Series and the SPI 26482 Series 1 Commercial circular connectors. These connectors are compact, durable and compatible with different components, making it easier to find substantially equivalent parts.
How ElectroShield Can Help
Welding cobots are becoming more common as manufacturers seek out solutions for working smarter with fewer trained welders. While cobots can improve quality while saving time and money, they can add complexity, frustration, and unexpected costs if they aren’t well-designed. Working with an experienced connector distributor like ElectroShield that carries parts from world-class manufacturers can help you find the right solution for your welding application.
Our connector experts understand the challenges of your industry and can help you find the best options for a new or existing application, whether you need to meet specific criteria outlined in a spec sheet or find equivalent parts fast.
Learn more about our connector solutions for welding, and connect with us for peace of mind.
