In an industry challenged by skilled labor shortages and increasingly complex manufacturing demands, cobots are proving to be valuable solutions in welding operations. As fabrication shops face growing pressure to maintain quality while increasing productivity, the use of 7-axis technology is stepping in to address the challenges surrounding automated welding applications.
The skills gap reality
The welding industry, like many industrial sectors, is facing a significant workforce crisis. According to the Manufacturing Institute, the skilled trades sector is projected to have 2.4 million unfilled jobs by 2028 with welding positions representing one of the most critical areas of concern.
This shortage isn’t just a matter of headcount – it represents a critical skills gap. Becoming a skilled welder requires extensive training and experience, assets that are increasingly scarce in today’s labor market. When companies invest in welding automation, they aren’t replacing welders but rather optimizing their valuable skills.
evaluating other available robot platforms.
Robots are best used when programmed for repetitive, less complex jobs, which empowers skilled welders to perform tasks that truly require their expertise. In many facilities, welders are performing the same welds thousands of times. Skilled welders should instead be able to focus on applications that demand their specialized knowledge.
7-axis advantage
While 6-axis robots have become commonplace in many welding environments, 7-axis, or 7-joint, robots deliver distinct advantages that particularly benefit welding applications.
Two critical parameters in any welding operation are maintaining the correct torch attack angle and ensuring constant travel speed. These factors directly impact weld quality, penetration depth and overall strength. The additional axis, or joint, addresses both challenges with remarkable efficiency.
With a seventh degree of freedom, robots can maintain a constant speed regardless of orientation. A 6-axis robot operates within much stricter parameters and often can’t maintain that constant speed, especially when transitioning between straight and curved lines.
evaluating other available robot platforms.
The implications for real-world applications are significant. Many welding operations using 6-axis robots require parts to be repositioned during the welding process. For example, after welding two sides of a component, operators must often stop production to flip the part so the robot can access the remaining sides. With a 7-axis robot, this manual intervention becomes unnecessary, as the additional axis allows the robot to maneuver around the entire part without repositioning, significantly improving cycle times and workflow efficiency.
The seventh axis also provides enhanced collision avoidance capabilities, allowing the robot to navigate around fixtures, clamps and other obstacles that might be present in tight welding environments. This becomes particularly valuable when working with complex geometries or when multiple parts need to be welded in sequence without repositioning.
Engineering reliability
Welding environments present harsh conditions that can challenge robotic equipment. Heat, splatter and constant operation demand robust construction that can withstand these rigors without frequent maintenance or failure.
Full metal construction with only minimal plastic components used for gaskets, joint seals and interior wire clips provides significant advantages. The anodized aluminum body offers superior resistance to the harsh conditions typical in welding operations.
Many robots use plastic components that can melt or burn in welding environments. Metal construction significantly reduces maintenance concerns and extends operational life in challenging settings.
The durability factor proves especially important for smaller fabrication shops that can’t afford equipment downtime. When a robot represents a significant capital investment, reliability becomes a crucial consideration in the selection process.
Non-expert programming
One of the most significant barriers to adopting robotic welding has traditionally been the complexity of programming and setup. Modern robots incorporate intuitive programming options that don’t require extensive robotics training.
The teach-point method allows operators to manually position the welding torch at the desired location, capturing points along the intended weld path. This hands-on approach is particularly valuable for fabrication shops where workers understand welding, but may lack formal robotics training.
For more complex applications, robots can include STEP file programming capabilities, allowing users to upload digital files to define weld paths. This functionality enables even small fabrication shops to quickly implement automated welding for custom fixtures and specialized components.
Programming flexibility extends beyond simple path creation. Modern robot interfaces allow welders to specify parameters like travel speed, approach angles, torch angles and dwell times at specific points – all critical factors that impact weld quality. This level of control ensures consistent results across production runs while making it straightforward to adjust parameters when working with different materials and joint configurations.
Easy integration
The ability to integrate with existing welding power sources and peripheral equipment represents another significant advantage of 7-axis robots in welding applications. Rather than requiring manufacturers to replace their entire welding infrastructure, these robots can work with a wide range of industry-standard welding equipment.
This flexibility extends to both basic and advanced welding technologies. The robot can communicate with these devices to coordinate timing, adjust parameters in real time and ensure optimal performance throughout the welding process.
For shops with multiple welding stations or diverse equipment needs, this compatibility significantly reduces the barriers to automation implementation. It also provides a clear upgrade path as welding technology advances, allowing fabricators to update components of their system without replacing the entire cell.
Real-world success
Spartan Robotics, a division of BlueBay Automation, specializes in collaborative robotic welding solutions and integrated Kassow Robots’ technology into the Spartan welding cell after extensive evaluation of available robot platforms.
Traditional robotic systems, such as industrial robots and other 6-axis robots, proved inadequate for performing complex welds in confined spaces and often struggled with obstacle avoidance in cluttered environments, which is critical when welding in tight areas.
After implementing the 7-axis design, Spartan Robotics reported significant improvements in welding precision, particularly in hard-to-reach areas. The enhanced maneuverability allowed their system to perform complex welds where other robots fell short.
Reliability benefits
For smaller fabrication shops, reliability can be transformative. These operations often struggle with production consistency due to their limited workforce. A robotic welding system enables them to maintain consistent quality while freeing their skilled personnel to focus on creative tasks.
This consistency extends beyond weld quality to production scheduling. By automating repetitive welding tasks, manufacturers can better predict completion times, optimize material flow and improve overall facility productivity – benefits that directly impact bottom-line performance and customer satisfaction.
Future of cobots
As collaborative robotic technology continues to evolve, the range of welding applications that can be effectively automated will expand. The flexibility inherent in Kassow’s 7-axis design positions the company to address challenges in custom fabrication environments where traditional automation has struggled. The world of custom fabrication is so large that welders are often never welding the same parts twice. Suppliers need to continue to break down barriers on what can and can’t be welded with a robot, allowing more flexibility in the robotic welding space.
By focusing on ease of use, enhanced maneuverability and robust construction, suppliers are helping fabricators of all sizes implement automation in applications previously considered too complex or variable for robotic welding. The integration of flexible, reliable 7-axis robots offers fabrication shops a powerful tool to address both their current challenges and future opportunities in a rapidly changing industry landscape.
