Benefits of Automating MAG Welding with Robots
MAG (Metal Active Gas) welding is one of the two types of GMAW (Gas Metal Arc Welding) processes. MAG is one of the most common industrial welding methods. It is particularly popular with robotic automation. Below is a list of some of the key benefits of automating MAG welding with robots.
- • Easy to Automate - One of the reasons robotic MAG welding has become so common in manufacturing is its ease of automation with industrial robots. Switching from manual MAG welding to robotic MAG welding is fairly straightforward, keeping interruptions to productions to a minimum. Many power supplies have the capability of powering both manual and robotic MAG applications, preventing users from having to invest in all new welding equipment. The FANUC Arcmate 120ic can be integrated easily with the Lincoln Powerwave R350 for automating MAG welding.
- • Reduces Cycle Times - MAG welding is one of the fastest welding methods. The prevention of spatter and the use of a filler wire allow for welds to be completed in less time than other robotic arc welding applications. Automating this process with welding robots further speeds up welding, reducing cycle times. Articulated robots are incredibly efficient, moving from weld to weld without breaks or delays. They operate at much faster speeds than human workers and their pinpoint accuracy prevents errors and rework.
- • Improves Weld Quality - Weld quality will be significantly improved by automating MAG applications with industrial robots. Industrial robots have high repeatability ensuring accuracy and that they stay within the programmed parameters. Welds will turn out clean, smooth, and even which helps extend the durability of the weld. Active shielding gas prevents the weld pool from becoming contaminated, further ensuring high weld quality.
- • Consistency - Automating with industrial robots provides consistency to your MAG application. Weld quality is replicated with each part ensuring all workpieces are uniform to one another. Robots are able to operate at the same speeds and times each day bringing consistency to productivity rates. Implementing the Yaskawa MA1440 for MAG applications will result in a reliable welding system.
- • Higher Productivity - Manual welding is a much slower process than robotic welding. It can be physically taxing for welders, causing them to take breaks during welds which negatively impacts productivity. Arc welding robots are fast and can operate around the clock with no stoppages. Just one FANC Arcmate 100ic can handle the same workload as up to three welders. Automating MAG applications with robots will increase throughput and productivity rates.
- • Lowers Production Costs - It seems these days production costs are always rising but automating MAG applications with six axis robots can combat cost increases. Welding robots eliminate expensive welder salaries. Their accuracy reduces errors that can lead to the use of more materials. They also are able to better conserve consumables. All of these translate into robots lowering production costs for manufacturers.
- • Flexibility - Automating MAG welding with robots allows for greater manufacturing flexibility. MAG welding robots can be used to weld a wide variety of metals. They can easily adapt to production changes with the ability to automate other arc welding applications. The ABB IRB 2400-16 can be switched from MAG welding to automated MIG welding with little downtime.