Collaborative robots (cobots) are increasingly becoming a go-to solution for welding tasks, offering flexibility, safety, and a faster return on investment than many traditional automation options. In welding applications, ease of programming, software capabilities, and ecosystem support can make all the difference.

We’ve compared six leading cobot brands for welding based on five key factors:

• Ease of use – How quickly an operator can learn and program the cobot.
• Welding features – The richness of built-in or add-on welding capabilities.
• Support and documentation – Availability of help, manuals, training, and community resources.
• Quality – Precision, robustness, and reliability.
• Price – Affordability relative to performance.

We also list each brand’s global cobot market share (across all applications, not just welding) to give an idea of market maturity and integration possibilities.

Universal Robots

Cobots: e-series (Ur3e, UR7e, UR12e, UR16e), UR Series (UR15, UR20, UR30)

Welding Software: Smooth Robotics (SmoothTool), Hirebotics, Vectis Automation, Wecobot, and more

Global Cobot Market Share: 33.6%

Scores: Ease of use – 5 | Welding features – 5 | Support – 5 | Quality – 5 | Price – 3

Total Score: 4.6

Universal Robots (UR) leads both in market share and user-friendliness.

With a huge ecosystem of welding software options and a simple programming interface, UR is a favorite for both beginners and experienced welders.

While the hardware comes at a premium, the strong support network and flexibility justify the investment.

  ABB

Cobots: CRB 15000 (GoFa 5, GoFa 10, GoFa 12)

Welding Software: ABB Cobot Arc Welding Package

Global Cobot Market Share: 14.3%

Scores: Ease of use – 3.5 | Welding features – 4 | Support – 4 | Quality – 5 | Price – 4

Total Score: 4.1

ABB combines high-end hardware quality with robust, integrated welding software.

Their cobots are precise and reliable, though the learning curve is slightly steeper compared to UR.

An excellent choice for companies that value long-term performance and advanced features.

 Fanuc

Cobots: CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-20iA/L, CRX-30iA

Welding Software: Fanuc ArcTool software

Global Cobot Market Share: 11.5%

Scores: Ease of use – 3 | Welding features – 4 | Support – 4 | Quality – 5 | Price – 3

Total Score: 3.8

Fanuc’s CRX series offers highly durable hardware and proven reliability.

ArcTool software provides solid welding features, but the programming interface is less intuitive, making Fanuc best suited for teams with technical expertise or prior robotics experience.

 AUBO

Cobots: AUBO-i3, AUBO-i5, AUBO-i7, AUBO-i10, AUBO-i12, AUBO-i16, AUBO-i20

Welding Software: Copilot / IntelliSet (Miller)

Global Cobot Market Share: 2.8%

Scores: Ease of use – 3.5 | Welding features – 3 | Support – 3.5 | Quality – 3 | Price – 5

Total Score: 3.6

AUBO stands out for its affordability, especially for smaller welding operations.

While it doesn’t match the build quality of higher-priced brands, its cost-effectiveness makes it appealing for lighter workloads or budget-conscious businesses.

  Doosan

Cobots: A-series, M-series, H-series

Welding Software: Third-party solutions

Global Cobot Market Share: 4.2%

Scores: Ease of use – 3 | Welding features – 3 | Support – 3.5 | Quality – 4 | Price – 4

Total Score: 3.5

Doosan delivers solid performance with good build quality, though welding features depend heavily on third-party integrations.

It’s a capable mid-range choice but lacks the ecosystem depth of UR or ABB.

  Han’s Robot (Huayan Robotics)

Cobots: Elfin series, other collaborative models

Welding Software: Third-party solutions

Global Cobot Market Share: Small but growing in Asia

Scores: Ease of use – 3 | Welding features – 3 | Support – 3 | Quality – 3,5 | Price – 4

Total Score: 3.3

Han’s Robot is a rising player in the cobot market, with competitive pricing and an expanding presence in Asia.

Welding solutions generally require third-party software, and global support infrastructure is still developing, but it’s one to watch for cost-effective deployments.

Final Thoughts

Our comparison shows that Universal Robots remains the top choice for welding applications, thanks to its ease of use, rich software ecosystem, and strong global support.

ABB and Fanuc offer high-quality, reliable alternatives, while AUBO and Han’s Robot deliver budget-friendly options. Doosan sits in the middle ground, with good quality but fewer welding-focused tools out of the box.

Disclaimer: This review and its scores are based on research conducted by Smooth Robotics. We work closely with Universal Robots, and our SmoothTool welding software is built specifically for UR cobots. While we’ve aimed to keep this evaluation as objective as possible, our experience inevitably gives us deeper insight into the UR ecosystem.

FAQ: choosing a cobot for welding

Which cobot is best for welding?

In our comparison, Universal Robots scores highest overall (4.6 out of 5), thanks to ease of use, its welding software ecosystem and global support. ABB (4.1) and Fanuc (3.8) follow, and the best fit still depends on your budget and workload.

Which cobot brand is the most affordable for welding?

AUBO scores highest on price (5 out of 5), followed by Doosan and Han’s Robot (4 each). In our assessment, the lower prices come with lower scores for welding features.

Do I need extra software to weld with a cobot?

Usually yes. A cobot needs welding software or a welding package to control the welding process and make programming easy. The options differ by brand, as listed in each section above.

Which welding power sources work with SmoothTool?

SmoothTool supports power sources from Kemppi, Miller, ESAB, OTC, Fronius, Lorch, EWM, Megmeet and Lincoln Electric. See the power source integrations.

In cobot welding, flexibility, efficiency, and precision are essential. SmoothTool, our welding package built specifically for Universal Robots, stands out by offering something many systems don’t: broad compatibility with a wide range of welding power sources.

Rather than locking customers into a specific brand or system, SmoothTool is designed to work with what you already have. Our goal is simple—make it easy for manufacturers to adopt automation without having to replace a trusted power source brand.

Designed Around Your Welding Setup

At Smooth Robotics, we recognize that every production setup is different. Many businesses have long-standing preferences for specific power source brands or models. Forcing a switch just to enable automation doesn’t make sense—and it’s not something we believe in.

That’s why we’ve invested in building and maintaining a large library of supported power sources. These integrations allow you to use SmoothTool with your existing welding infrastructure, helping you move forward with automation at your own pace, on your own terms.

What “Pre-Integrated” Really Means

When we talk about “pre-integrated” power sources, we mean more than just basic compatibility. Each of these integrations is developed to give you deeper control from within the SmoothTool interface, right on the robot’s teach pendant.

You can make dynamic adjustments to weld parameters like amps, volts, and wire feed speed anywhere in your welding program. This gives you the flexibility to optimize for different material thicknesses or part geometries—all without reprogramming or manual tweaks.

Depending on the integration, other useful features, like wire jog, gas test, or air blow—are also available in the interface. Some of our power source integrations even support guided wizards to help set up jobs based on material type, wire selection, or process recommendations.

You’ll find a full list of our supported power sources on our website. It’s a growing list, reflecting our ongoing work to keep SmoothTool compatible with the most widely used and reliable systems on the market.

The RetroFit Kit: A Practical Option for Broader Compatibility

Not all power sources support full integration. That’s where our RetroFit Kit comes in. It’s a straightforward way to connect existing manual welding units to your robot cell.

The kit comes in three versions (Euro, Miller, and Lincoln connectors), covering most commonly used welding machines. It lets you get started with robotic welding using the equipment you already own, without needing to make big upfront investments.

The main difference from our full integrations is control. With the RetroFit Kit, you can automate the welding process, but adjustments to settings like amperage or wire speed still need to be made directly on the machine—not from the robot’s program.

Even so, the RetroFit Kit offers a practical way to begin your automation journey while maintaining flexibility for future upgrades.

Built on a Commitment to Openness

We believe cobot welding should work around your needs, not the other way around. That’s why SmoothTool is built with power source agnosticism as a core principle. We continuously expand and maintain our integrations so our customers aren’t locked into a single brand or ecosystem.

As new models come out and customer needs evolve, we stay focused on keeping SmoothTool compatible, capable, and easy to use—no matter what power source you’re working with.

In Summary

SmoothTool gives you the flexibility to automate your welding without being limited by your existing equipment. Whether you’re using a fully supported, pre-integrated power source or connecting through the RetroFit Kit, SmoothTool offers a clear path into cobot welding.

With powerful software, easy-to-use interfaces, and a strong focus on compatibility, SmoothTool helps manufacturers improve efficiency and reduce complexity—without sacrificing control or quality.

Discover the power of SmoothTool, the ultimate cobot welding solution for Universal Robots.

This groundbreaking technology combines the precision and repeatability of robotics with the flexibility and craftsmanship of manual welding.

With its intuitive no-code software, welders can effortlessly create complex welding paths without extensive programming knowledge.

The user-friendly programming flange allows for hands-on movement and point-by-point teaching of the welding trajectory. Experience the future of welding and empower yourself with SmoothTool.

The realm of manufacturing is witnessing a significant transformation with the integration of collaborative robots, or cobots, into various processes.

In our pursuit of efficiency, we embarked on a mission to explore the speed advantages offered by cobots in MIG welding.

This experiment aimed to compare the conventional manual welding approach with the potential time savings achievable through cobot-optimized welding parameters.

The Test Setup

To conduct the comparison, we utilized the Kemppi Master M power source with Abicor Binzel robotic torch kit for both test welds.

The first run adhered to the recommended parameters from Kemppi Weld Assist, a valuable tool that assists welders in determining optimal settings based on factors such as material type, plate thickness, and weld type.

For the second run, we increased the travel speed to maximize time efficiency without compromising the quality of the weld seam.

Test Piece

Our focus centered on a T-joint fabricated from two plates of 4mm unalloyed black steel. The welding process involved a double fillet MIG weld on three identical test pieces securely positioned in a jig.

Robotic Assistant

Executing the welding tasks was the UR10e from Universal Robots equipped with SmoothTool from Smooth Robotics, showcasing the prowess of collaborative robotics in industrial applications.

Results

Recommended Parameters for Manual Welding

Cobot-Optimized Travel Speed

Efficiency Gains

In an 8-hour workday, the advantages of cobot-optimized parameters become even more apparent:

Cobot-Optimized Welding:

• Sets of 3 Pieces: 192 sets
• Total Items Welded: 576 items

Manual Welding with Recommended Settings:

• Sets of 3 Pieces: 152 sets
• Total Items Welded: 456 items

This translates to a remarkable 26% increase in productivity during a single 8-hour day when employing cobot-optimized parameters.

Discussion

In examining the welding outcomes, it’s evident that the manual welding run produced slightly thicker weld seams and throats, in adherence to Kemppi Weld Assist’s recommendations.

However, the throat thickness aligns with the accepted industry standard for black steel of at least 0.8 times the plate thickness, ensuring weld integrity.

Minimum accepted throat thickness: 4mm X 0,8 = 3,2mm

3,8mm > 3,2mm

Considering an 8-hour workday, our calculations assume a 100% duty cycle, implying continuous welding.

Changeover times for the next batch remain constant for both methods, minimizing any impact on the observed productivity gains from cobot-optimized parameters.

As we explore avenues for additional speed optimization in welding processes, it becomes evident that specialized features designed to ensure deep weld penetration during high-speed welding can play a pivotal role.

Technologies such as the Max Speed feature from Kemppi or the ForceArc Puls feature from EWM exemplify this approach. These innovations focus on refining the welding arc dynamics, enabling faster travel speeds without compromising penetration depth.

Incorporating such specialized welding processes has the potential to further enhance the efficiency gains witnessed in our cobot-optimized parameters experiment.

By leveraging these advanced features, manufacturers can unlock even greater productivity while maintaining the structural integrity of welds, marking a promising evolution in the landscape of industrial welding.

Conclusion

The experiment clearly shows how collaborative robots can greatly improve the efficiency of welding.

By using parameters that are optimized for cobots, manufacturers can increase production rates while still maintaining high-quality welds.

As industries increasingly adopt automation, integrating cobots into the welding process is an exciting way to achieve new levels of productivity and efficiency.

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Welding, an age-old craft that forms the foundation of structural stability, stands at the edge of an evolution. Join us as we explore the future of welding in this blog post, where we take a closer look into the way welding cobots are reshaping the industry.

Current Welding Landscape

Welding, an important part of the manufacturing and construction industries, it has been the key to keeping structural integrity. However, it is dealing with an upcoming challenge—a rapidly aging workforce.

Statistics from the American Welding Society (AWS) reveal that 43.2% of welders are over 45 years old, indicating a pressing need for new talent.

The younger generation, though, seems to be distant from the field, largely associating it with outdated practices, an unglamorous working environment, and difficult manual labor. To spark interest and attract fresh talent, the welding industry needs a transformative shift, and automated welding emerges as the way to trigger this change.

The challenge posed by an aging welding workforce extends far beyond the borders of the United States. While the U.S. is a notable example, the issue is global in scale. In many industrialized countries, welders are the essential support of construction and manufacturing industries, and the demographic shift towards an older workforce presents a significant challenge.

Statistics from the European Union reveal similar trends. In countries like Germany, well-known for its engineering and manufacturing expertise, the average age of a welder is approaching towards the mid-50s.

The situation is like a problem that’s getting worse with time because the know-how and experience of these experienced welders are about to leave the workforce in the next few years.

In Asia, where industries are growing fast, the same thing is happening. In places like Japan and South Korea, the welding industry is dealing with two problems: older workers and younger people not being very interested in it. As industries keep growing, there’s a pressing need to make young generation interested in welding again.

The aging workforce is a universal concern, one that demands a global solution. Using automated welding systems can play a significant role in addressing this challenge.

Welding Cobots as a Fresh Perspective

In the welding world, automation isn’t just about robots taking over. It’s about making welding cool for tech-savvy young people. A lot of welding is still done the old-fashioned way. But now, we’re bringing in modern tech like laser welding and welding cobots.

This is changing how we see welding. It’s not just a simple job anymore; it’s a smart and exciting challenge that matches the high-tech world we live in today.

Welding cobots blend technology that fits with the digital age. Unlike old-school industrial robots with complicated controls and rigid routines, cobots are made to work with human welders and have user-friendly interfaces.

This tech combo makes learning about automated welding interesting and helps welders learn and improve in a fun and interactive way. It changes the image of welding from a dirty, manual job to an exciting and intellectual profession that matches what the new generation wants.

One of the most compelling aspects of welding cobots is their ability to democratize advanced welding technology – they make high-tech welding accessible to all.

Unlike industrial robots, these cobots aren’t limited to huge production lines. They can easily fit into operations of all sizes. This flexibility doesn’t just get people excited; it lets welders tap into their creativity by using cutting-edge tools that can handle all sorts of projects.

By merging traditional skills with modern tech, welding cobots introduce a fresh wave of creativity and job satisfaction into the welding field, particularly for Generation Z and beyond. This change blurs the line between manual work and modern technology, creating a world where both coexist seamlessly, providing a unique blend of human knowledge and technological excellence.

Understanding the thoughts and desires of the digital generation is crucial when attracting a younger workforce to the welding industry. This generation, often referred to as Generation Z, consists of individuals born between 1997 and 2012. They are true digital natives, growing up in a time of rapid technological progress and constant connectivity.

To attract this generation to welding, it is essential to align the profession with their values and aspirations. Studies and surveys have unveiled insights into the mindset of Generation Z:

By incorporating welding cobots, the industry can customize its products to connect with the goals of today’s young generation. The easy-to-use interfaces and the tech-savvy nature of cobots match the values and expectations of Generation Z.

Welding Cobots: Meeting Generation Z’s Expectations

Statistics and empirical data provide important insights into the role of automated welding in attracting new talent to the welding profession:

• A study by the American Welding Society (AWS) found that companies that invest in automation and modern technologies have a higher rate of welder retention and are more attractive to new talent. Young welders prefer workplaces that offer exposure to innovative technologies.

• The adoption of automation in welding has significantly improved workplace safety. Automation by putting welders in a safe proximity from fumes and toxic gases has led to a reduction in welding-related accidents.

• Automated welding processes are more efficient than manual welding. The increased speed of project completion attracts new talent, especially those who value efficiency and productivity.

• Welding cobots has led to the development of educational programs that cater to the digital generation. Vocational schools and technical colleges offer curricula that include training in automation and automated welding, further enhancing the profession’s appeal to young individuals.

• The introduction of automation enhances a company’s competitiveness in the market. According to the International Federation of Robotics (IFR), companies that have embraced automation increase productivity and competitiveness.

The Socioeconomic Impact of Welding Cobots

Welding cobots go beyond just their economic impact – they have a deep influence on society, changing how welders view and participate in work.

Automation empowers welders to handle a wider variety of projects, showcasing their skills and increasing job satisfaction. It also opens doors to more creative and challenging tasks. Additionally, integrating welding cobots creates a safer work environment, reducing exposure to risky conditions and improving the well-being of welders.

Despite concerns about job loss, welding cobots actually enhance job security. Welders who acquire skills in operating and maintaining these machines become invaluable assets to their companies.

Automation and technology are appealing to younger generations, and welding cobots blend traditional welding with modern tech, making them an attractive option for those who are tech-savvy.

The Global Adoption of Automation in Welding Industry

The widespread use of automated welding shows how this important change is happening all over the world.

Across continents, countries recognize the significance of welding cobots to address the challenges of an aging workforce and meet the evolving needs of the market.

• China: China, with the world’s largest manufacturing sector, has witnessed a rapid wave in the adoption of welding automation. The Chinese government has incentivized the integration of automation into manufacturing processes, aiming to improve efficiency and product quality.

• Europe: In Europe, the welding industry is experiencing a notable shift towards automation. The European welding industry, known for its commitment to quality and precision, is actively embracing automation to remain at the forefront of technological advancements.

• North America: The United States and Canada are also undergoing significant changes in the welding industry. Major corporations are investing in automation to streamline their operations and remain competitive in the global market.

Training and Education for the Future

Realizing the full potential of welding cobots calls for the development of robust training and education programs. These programs should cater to both experienced welders looking to enhance their skills and newcomers just entering the field.

• Upskilling Experienced Welders: For welders with years of manual welding experience, the transition to welding cobots is essential. They need access to training programs that introduce them to the operation and programming of automated welding systems. This retraining ensures that their expertise remains relevant in today’s industry.

• Educating the Next Generation: Educational institutions must adapt their welding curricula to the changing landscape. They should incorporate training on automation and welding cobots, equipping young talents with the skills they need to excel in the modern welding industry. Vocational schools and technical colleges play a crucial role in laying the foundation for future welders.

• In-House Training: Companies investing in automation should give high priority to in-house training programs. These programs empower their employees to become skilled in operating and maintaining automated systems. Collaboration with manufacturers of welding cobot systems can facilitate this training, ensuring a smooth transition into the world of automation.

The welding industry is at a turning point, with a clear direction towards automated welding. To secure its future and inspire the next generation of welders, the industry must adapt to the changing landscape, focusing on innovation, efficiency, and training. By investing in welding cobots and emphasizing comprehensive training and education, the welding industry can redefine itself. It can continue to be an important part of modern infrastructure and overcome labor shortage.

SmoothTool Cobot Welding Package

Embracing and investing in welding cobots and advanced machinery isn’t just a strategic move; it’s forward-thinking and visionary. These technological advancements are a response to the shortage of skilled welders and are reshaping the welding profession.

At this point it is important to mention our cobot welding solution SmoothTool. SmoothTool represents a harmonious blend of automation and human expertise, offering a glimpse into the exciting future of welding. It supports various welding techniques such as Metal Inert Gas (MIG), Metal Active Gas (MAG), and Tungsten Inert Gas (TIG), providing a comprehensive solution for a wide range of applications.

What truly distinguishes SmoothTool is its ease of use and accessibility. It empowers operators to quickly grasp how to program it, eliminating the steep learning curve often associated with automation.

• The Programming Flange: Programming flange empowers operators to ‘teach’ the cobot how the weld should be performed. It captures and links the positions and movements of the welding arm to the control box and programming software, ensuring a seamless transition from concept to execution.

• The Intuitive Programming Software: Operating on the teach pendant, SmoothTool guides welders through the process of configuring parameters for the weld. It facilitates the step-by-step teaching of the cobot, ensuring precise execution. The software additionally allows welders to review the tool path in the 3D Viewer without actual runs, ensuring efficiency and precision.

Conclusion: Shaping the Future of Welding

In conclusion, the welding industry is on a transformative journey, one that promises to reshape its image and secure its future. The challenges posed by an aging workforce and the declining interest among the younger generation call for an immediate action.

Automated welding offers a dynamic solution to these challenges. These technologies enhance precision, efficiency, and safety while promoting creativity and skill development.

The integration of automation is not just an economic investment; it is a socioeconomic transformation that empowers welders, enhances job security, and attracts a new generation of digital natives to the welding profession.

The statistics and empirical data shared in this blog post make a strong case for the benefits of using automation in welding. The potential for saving money, creating jobs, and becoming more competitive is truly significant.

Additionally, automation encourages a culture of innovation and progress that has a broad and positive impact on various industries and society as a whole.

At the forefront of this transformation is the SmoothTool Cobot welding package. With its ability to handle different welding methods, user-friendly programming, and collaborative features, it’s a real game-changer in the welding world.

It connects the dots between different generations, providing an entry point for young talent and a way for experienced welders to level up their skills.

In a world that’s increasingly turning to automation, the welding industry has a chance to reinvent itself by embracing technology and innovation. Opting for automated welding isn’t just about staying relevant; it’s also about attracting fresh talent and maintaining a vital role in today’s manufacturing and construction.

The future of automated welding looks promising, characterized by precision, creativity, and a harmonious fusion of human skills and technology.

With solutions like the SmoothTool cobot welding package, the welding scene is all set to ignite the passion and curiosity of a new generation of welders!

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Exploring Multipass Welding

A multipass weld is a weld that consists of a number of singular welds (or passes) layered on top of each other in a specific manner to create a bigger and stronger weld. This methodology is predominantly employed when welding thick sections, engaging in repairs, hard-facing surfaces, or in the course of build-ups. The strength of the joint with multipass is higher than what would be achieved with a single pass weld.

The technique takes into account various process and design considerations such as weld travel speed, weld pool shape, bead geometry, and the heat input of the weld. Modifications in these factors have direct effects on potential solidification cracks, which may occur in both single-pass and multi-pass welds.

In the multipass welding, weld bead depth-to-width ratio is a significant factor; narrower and deeper penetration welds can lead to higher transverse stresses during cooling compared to those with a suitable depth-to-width ratio where stresses are radially dispersed from the weld. It’s worth noting that the number of passes is generally influenced by the thickness of the material being welded – the rule of thumb being, the thicker the material, the more passes it necessitates.

Therefore, multipass welding, while more time-consuming than single-pass welding, affords increased strength and stress relief to the weld area, making it a preferred method for heavy-duty industrial applications. It further allows for precise temperature control, thereby minimizing the risks of hot/cold cracking. Each additional pass also extends the area of the weld, potentially enhancing its resilience depending on the specific application.

When is Multipass Welding Needed?

The necessity for multipass welding arises under several circumstances, grounded in the requirements of the workpiece and the welding process itself. Let’s explore when and why this technique might be employed.

Multipass welding becomes essential when the material’s thickness demands a weld bead size and root depth that can’t be achieved with a single pass. This usually pertains to the welding of heavy-duty components such as thick-wall tubes or full-floater housing ends, where achieving a robust joint with just one weld pass might be impracticable.

Another significant factor necessitating multipass welding is temperature regulation. If a large weld bead is needed but excessive heat input could compromise the integrity of the material, then a multipass weld becomes a sensible choice. This approach enables the material to cool down sufficiently between passes, reducing the risk of overheating, warping, or inducing other forms of thermal damage.

Moreover, the weld’s intended strength and rigidity play a crucial role in the decision to employ multipass welding. For instance, in applications where full strength design is required, welding rules of thumb suggest that the weld size should be 0.750 of the material thickness. Thus, achieving such a size with a single pass might be infeasible, making multipass welding an appropriate solution.

However, it’s important to note that unnecessary extra passes can have negative consequences, such as inducing additional surface warping, and increasing time and resource expenditure. Hence, the decision to employ multipass welding should be based on an accurate assessment of the material’s needs and the welding process’s requirements.

Multipass in SmoothTool: Exploring Available Features

The Multipass system in SmoothTool makes it easy and fast to set up a multipass weld and it lets you add as many passes as you need to get the right weld thickness. Once the base pass is taught, the Multipass system can auto-generate each additional pass based on user input. To achieve a perfect result, SmoothTool lets the user specify the travel- and work angles for each pass in the multipass weld. This level of control helps achieve the perfect result every time.

SmoothTool’s multipass welding system is equipped with numerous features that greatly enhance the effectiveness and versatility of multipass welding.

• Multipass Recreate: The Multipass recreate feature offers the possibility to save the pass structure and data of a Multipass program as a custom profile. You can then load and apply your unique Multipass profile on a new base pass. This feature comes in handy when you are performing multipass welds on similar pieces with a different shape, as it effectively shortens the setup time of these weld jobs. 

• Multipass Crop and Extend: In addition to Multipass recreate, we have also upgraded our Multipass feature with the crop and extend functionality, which allows individual passes to be shortened or extended on both ends. This is useful for making stair-like endings. You have full control over the parameters of each pass to achieve the highest structural integrity of the joint.

• Starting Point Selection: This is a function that enables you to start your weld from anywhere. This powerful feature provides the benefit of being able to choose any point in the 3D viewer and set it as your starting point of the weld. This means you no longer have to restart the weld program in order to resume welding in case of production disruptions, as you are able to navigate the cobot to continue welding seamlessly from any placement you choose.

• Change parameters both between and within the passes: The SmoothTool allows you to modify weld parameters on the power source between each pass and also within a single pass. This versatility brings you closer to meeting the specific requirements of your particular welding task.

With these advanced features, SmoothTool provides an efficient and versatile solution for multipass welding tasks.

SmoothTool’s Multipass Benefit: A Closer Look

The Multipass system in SmoothTool brings with it a suite of benefits that makes the process of multipass welding easier, faster, and more efficient. Here are the key benefits of the SmoothTool Multipass system:

Increased Efficiency: SmoothTool’s Multipass system is engineered for a quick and seamless setup of multipass welds. It allows the addition of as many passes as needed to achieve the desired weld thickness. Once the base pass is set up, the system can easily generate additional passes based on user input.

Optimal Control: SmoothTool provides flexibility in specifying the travel and work angles for each pass in the multipass weld. This control level aids in achieving optimal results each time, leading to efficient welding processes and robust joints.

Improved Productivity: The Multipass recreate feature lets you save the pass structure and data of a multipass program as a custom profile. This saved profile can then be used on a new base pass, significantly reducing the setup time for similar but differently shaped weld jobs.

Enhanced Versatility: The SmoothTool Multipass system includes the capability to shorten or lengthen individual passes at both ends. This feature provides complete control over each pass’s parameters, helping attain the highest joint structural integrity.

User-friendly Experience: The SmoothTool’s Multipass system is continuously enhanced with new features, such as extending and cropping passes, and saving and loading profiles. These improvements elevate the functionality and user experience.

Superior Temperature Control: In the multipass system you can specify the time between each pass. This control feature makes it an apt choice for tasks where excessive heat could jeopardize the material’s integrity.

Concluding Thoughts

SmoothTool, with its advanced Multipass feature, is a transformative tool that bridges the gap between the complexities of the multipass welding process and the increasing demand for superior weld quality. It is proof that technology, when harnessed correctly, can significantly augment traditional practices and contribute to the evolution of industries.

As the world of cobot welding continues to innovate and expand, SmoothTool remains at the forefront, integrating advanced features to ease complex processes like multipass welding. Indeed, the ability to meld traditional welding techniques with innovative software capabilities heralds a new era in the welding industry, one marked by unprecedented control, adaptability, and efficiency.

Are you intrigued by the potential of SmoothTool’s Multipass feature and how it can revolutionize your welding tasks? We invite you to explore our other articles to learn more about the features available in our SmoothTool cobot welding package. Continue your journey into the world of cobot welding, and discover how our technological offerings can enhance your productivity margin.

Visit our YouTube channel to see more videos of multipass welding in SmoothTool!

1. Are you having trouble finding skilled welders?
2. Do you want to increase your productivity?
3. Do you weld parts that fit on a 2×1 m table?

If you can answer yes to those three questions, then you are more than likely to benefit from introducing a cobot welder to your team.

Read on to learn more about how cobot welding can benefit your company and what kind of tasks are the right fit for the robot welder.

Cobot Welder vs Robotic Welding Cell

To understand who can benefit from adding a cobot welder, we need to establish what a cobot welder is and what it is not.

A cobot welder should be seen as the welder’s tool and not as a fully automated robotic cell that can do work without human input.

The cobot needs to be operated by a human just like any other tool that the welder uses, and it needs input from a skilled welder to perform optimally. It does, however, not need input from a specialized robotic programmer like in traditional welding automation.

The safe nature of the collaborative robot makes it possible for the welder to be hands-on with the robot and move it around to teach it the welding path. This is in stark contrast to traditional welding automation, where industrial robots must be placed behind a safety perimeter and would be very dangerous to stand next to while running.

An industrial robotic welding cell will many times be part of a larger automation process where no or very little human input is needed once the programming is done. This setup can be viewed as fully automated but is very costly to implement and reprogram. This setup is a good fit for manufacturing processes with a high volume and low mix.

A cobot welder doesn’t need a dedicated floor space or safety perimeter and it is portable. It can be programmed quickly by your welder and doesn’t require a trained robotic programmer. It is a great fit for smaller manufacturers with a lower volume and higher mix. It is a flexible solution, that can be deployed quickly and at a lower cost.

Let The Cobot Do the Grunt Work!

To have a successful implementation of the cobot welder, the manufacturer must learn to use the cobot for the right tasks. Many new users are tempted to automate very complex welding jobs straight away, but in our experience, we see that starting out with simpler welds is the better approach.

The cobots excel with welds that have a long arc time and with circular welds that would be difficult to perform manually in one take. Basically, all the grunt work that is tedious and physically straining to do by hand.  

By starting with all the low-hanging fruit in terms of welding tasks, you will get a quick return on investment and gain familiarity with the new tool.

You will also quickly figure out where the cobot can increase productivity straight away, where and how you can modify your current production flow to implement the cobot, and where it doesn’t make sense to use the cobot.

Once you’ve automated all the low-hanging fruit and gotten familiar with the cobot, you can begin to investigate breaking the more complex jobs into multiple simpler welds and produce the right fixtures and jigs for those parts.  

Harness the Expertise of Your Skilled Welders

Getting the robot to do all the monotonous and repetitive welds frees up your skilled welders to perform more advanced procedures thereby using their acquired expertise and craftsmanship. This could be performing complex welds that are not a good fit for the cobot, setting up new programs on the robot, or it could also be testing and creating jigs and fixtures to be used with the cobot.

Skilled Welders are in short demand which means they are expensive and hard to find, so having them doing tedious and monotonous simple welds all day doesn’t make sense. It will not only give you a bad return on investment, but it will make your welders look for better job opportunities.

Giving your welders the best tools available will make them more productive, happier, healthier, and less likely to look for other job opportunities.

Advanced features

The true strength and benefit of a cobot welder stems from the fact that it is a hybrid solution taking the best attributes from both manual and robotic welding and getting rid of the downsides.

You get the fast changeover time and real-time human quality assurance from manual welding but without a lot of the safety and health issues, and you get the productivity and consistency benefits from traditional welding automation, but without the need for complex programming.

It is however important to keep in mind that a hybrid also comes with some compromises and that the cobot welder functions best when used for tasks that are within its intended capabilities.  

A basic cobot welding setup will be able to handle most of the welds that the manual welder can do and some of the welds that a traditional welding automation setup can do. Cobots are generally smaller and slower than traditional industrial robots and thus can be limited in terms of reach and number of welds per minute.

Advanced features like seam tracking, touch sense, external axis manipulators, and camera vision can be used with a cobot, but they are normally better suited for traditional robotic welding. In many cases, upstream processes and cleverly crafted jigs can make the advanced welding features unnecessary. However, if that’s not possible, you need to consider carefully whether a cobot is the best fit for welding tasks that require these advanced features.

Seam Tracking

Consider the case of seam tracking — a valuable capability tailored to instances involving extensive and irregular welds. Seam Tracking employs advanced sensing technology to rectify welding trajectories, effectively compensating for deviations from the initial path.

Although seam tracking is a useful feature, it is important to know its limitations and the consequences it can have on productivity.

When setting up a welding program using seam tracking technology, it’s important to acknowledge that the setup process might be more time-intensive due to heightened intricacy. Should you choose to employ Through the Arc Seam Tracking (TAST), the robotic system is required to adopt a weaving pattern, inevitably leading to an augmentation in welding duration.

It is also important to recognize certain constraints associated with this approach. Notably, TAST is unsuitable for welds involving thin plate thickness, and it’s also incompatible with Aluminum welding.

SmoothTool, the cobot welding solution by Smooth Robotics has several advanced features in the software. There are no paywalls in the software and all features are available to all users with a valid license. This allows for experimentation with welding techniques that would normally be suited for an industrial robot, but we strongly recommend beginning with automating the simple, but time-consuming welds before dabbling with welds that require advanced features.

The greater the complexity of a collaborative robot (cobot) setup, the more it will resemble traditional welding automation. This, in turn, leads to increased programming skill requirements and job-switching times, which curtails the advantages of having a cobot welding setup.

Summing it up

In conclusion, if you’re grappling with the challenge of finding skilled welders, aiming to enhance productivity, and dealing with parts that fit within a 2×1 m table, the introduction of a cobot welder to your team could be a transformative solution.

A cobot welder operates as a collaborative tool, bridging the gap between manual and robotic welding. Unlike fully automated robotic cells, cobots require human guidance for optimal performance, eliminating the need for specialized robotic programmers.

The safety afforded by collaborative robots allows hands-on interaction and easy teaching of welding paths. While traditional industrial robotic welding suits high-volume, low-mix manufacturing, cobot welders offer portability, quick programming by welders, and cost-effective deployment for smaller manufacturers with varied needs.

By automating simpler welds first, businesses can swiftly reap returns on investment and identify productivity enhancements. The cobot welder amalgamates the best of manual and robotic welding, yielding efficiency gains without intricate programming. However, it excels within its capabilities, and advanced features might be more suitable for traditional robotic welding setups.

As you consider cobot welding, starting with simpler welds and gradually exploring more complex tasks can optimize your deployment.

Smooth Robotics’ Cobot Welding Solution, SmoothTool, offers advanced features to all users, emphasizing experimentation while urging prioritization of simple yet time-consuming tasks. The key lies in aligning the cobot’s capabilities with your welding needs, avoiding over-complexity to preserve the advantages of this collaborative and efficient solution.

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Costs of robotic welding power sources are huge! Right…?

And cost is the main barrier of entry for welding automation. It is too expensive for small companies to get started with robotic welding. The capital expenditure for a robotic welding cell is simply too large for the current budget and besides, robot welding only makes sense for large companies with big batch sizes…

But is that true?

What if we told you that you could use your existing manual welding power supply to get started with robotic welding? And that your new robotic welding solution comes with intuitive no-code programming software that requires minimal training of your employees and makes small batch welding profitable due to extremely quick change-over times?  

All of this is possible with the SmoothTool cobot welding kit from Smooth Robotics.

Read on to learn more!

Cobot welding

Cobot welding is a type of robotic welding where you use a collaborative robot instead of a traditional industrial robot to do the welding.

Using collaborative robots for welding comes with a bunch of benefits, such as:

• Smaller footprint – No fencing or off-limit area is needed due to the inherent safety features of the collaborative robot.
• Easy to program – Unlike industrial robots that require skilled programmers to set up a new weld, the cobot welder comes with SmoothTool’s intuitive no-code welding software.
• Profitable for smaller batches – The quick changeover time makes cobot welding a viable solution for companies with smaller batch sizes.
• Low startup cost – The possibility for retrofitting combined with minimal training and fast installation, makes it a low-cost and quick way to get started with welding automation.

Retrofitting

The Retrofit Kit by Smooth Robotics allows you to easily integrate your existing power source with SmoothTool. If you have a welding power source that uses a Euro Connector, you can transform it into a powerful robotic welding unit by adding a cobot, SmoothTool, and the Retrofit Kit.

Retrofitting provides an entry-level solution for those eager to explore the realm of cobot welding, while still capitalizing on their existing manual welding power source. Our Retrofit Kit allows businesses to conveniently link their manual power source to automated welding systems, simplifying the transition with a few key components. It eliminates the challenge of adapting to a new power source.

The retrofit kit ensures a direct and efficient interface between the manual welding power source and the robot, providing an uncomplicated path towards the adoption of welding automation. Retrofitting, therefore, stands as a more affordable and simpler alternative for those looking to dip their toes into cobot welding using their existing welding power supply.

However, it’s crucial to understand that while retrofitting provides a cost-effective gateway into cobot welding, it should not be considered superior to an automatic power source. In essence, we endorse retrofitting as a means to break down barriers and ease the initiation into cobot welding. However, we also advise keeping sight of the considerable advantages that transitioning to cobot welding with an automatic power source can provide as your automation requirements progress.

How it works

Retrofit Kit consists of the connector plate, adaptor, and feedback shunt. The Connector plate comes with additional connections and sockets for digital inputs and outputs. The Adaptor fits on the euro connector between the hose and the power sources and provides the input signal from the robot. And finally, the feedback shunt is a clamp that goes on the ground cable and provides the feedback signal to the robot.

Benefits of retrofitting with your existing manual welding power source

• 1. Cost-Effective: One of the main barriers for small businesses in adopting welding automation is the cost. The Retrofit Kit helps companies to automate their welding process by using their existing welding power source, which significantly reduces the upfront costs of introducing cobot welding. The retrofitting possibility, combined with minimal training and fast installation, makes this a low-cost and quick way to start welding automation. This lower barrier to entry can make cobot welding accessible to more businesses.

• 2. Seamless Integration: The Retrofit Kit is expertly designed for effortless integration with any welding power source using the Euro Connector. Comprising a connector plate, adaptor, and feedback shunt, these components work in unison to smooth out the connection process, transforming it into an uncomplicated and efficient task. The focus is not only on compatibility but also on simplicity, ensuring that the transition to automation becomes as smooth as possible. It eliminates the need to deal with a multitude of cables, providing a straightforward method of connecting your old power source to the robot. This ease of integration reduces setup time, minimizes potential errors, and enables a quicker return to operational efficiency, all of which underline the value of the Retrofit Kit for your welding automation journey.

• 3. Revival of Old Equipment: The Retrofit Kit breathes new life into older, reliable manual welding power sources by making them compatible with modern cobot welding applications. This means businesses can significantly extend the lifespan of their existing equipment, fostering sustainability by reducing waste and saving valuable resources. This also presents a cost-effective way to modernize operations, taking advantage of the reliability and proven efficiency of older equipment. Rather than discarding and replacing, the Retrofit Kit allows you to repurpose and use your machinery, simultaneously preserving past investments while driving forward into the future of welding automation.

• 4. Prevention of New Learning Curve: With the Retrofit Kit, businesses can use their existing welding power source, avoiding the need to familiarize themselves with a new system. This means they can sidestep the time and resources typically required to learn and adapt to a new power source. This is not only cost-effective, as it eliminates the need for an additional investment, but it also enables businesses to focus on the more essential tasks at hand.

• 5. Risk Mitigation: The final but no less important advantage of the Retrofit Kit is the way it reduces the risk associated with automation. Making a significant investment in cobot welding always comes with some degree of uncertainty, especially with concerns about whether the robot will be a good fit for your specific production type, or adaptability to changes in your business environment. The Retrofit Kit alleviates a portion of this risk by eliminating the need for investing in a new power source, thus lowering the overall investment. With less capital tied up in the power source, the risk associated with such an investment is effectively diminished. Plus, the robot can always be resold, providing a viable exit strategy if your needs change in the future. In essence, the Retrofit Kit provides a safer entry point into the world of automated welding.

Manual power sources vs automatic robotic power sources

For those concerned about the costs of acquiring a new power source, it’s important to consider the viable alternative of utilizing your existing manual welding power supply. Especially for small businesses operating within budget constraints, having an easy-to-use option that capitalizes on the existing welding power supply can be absolutely essential. This is where the SmoothTool Retrofit Kit comes in.

The SmoothTool Retrofit Kit enables seamless integration of existing manual power sources into the automated welding system. This allows you to experience the benefits of automation without the need for a costly upgrade or extensive retraining. While using the manual welding power supply with the SmoothTool Retrofit Kit offers a cost-effective and convenient way to enter welding automation, it’s important to understand its limitations.

When using a manual welding power source, parameters are controlled on the power source, which means that changes on the fly are not possible unless you manually adjust them while welding. The robot’s role is confined to turning on and off the welding. This limited control and flexibility might pose challenges to operations requiring more precision and customization.

In contrast, automatic robotic welding power sources provide advanced control over welding parameters. With an automatic setup, you can make parameter changes on the fly, directly inserting where the parameters should change in the program. The ability to change jobs and parameters directly from the robot teach pendant simplifies the operation and increases efficiency. Further, automatic power sources often come with advanced features such as adaptive welding capabilities, the ability to move wire back and forward, perform gas tests, and integrated software interfaces.

As your business grows and evolves, you might consider transitioning to an automatic robotic welding power supply to unlock these possibilities. The Retrofit Kit offers a valuable steppingstone towards automation by helping to use a manual welding power supply. While manual power sources have limitations compared to automatic robotic power sources, they provide a practical starting point for businesses to experience the benefits of welding automation.

Therefore, it’s important to choose the right power source option based on your specific needs and goals and embark on your journey towards a successful welding operation. Keep in mind the relative pros and cons of manual versus automatic power sources, and choose the one that best fits your operation’s scale, budget, and technical requirements.

Conclusion

SmoothTool cobot welding kit offers an alternative cost-effective solution for small businesses to enter the world of welding automation. By retrofitting existing manual welding power supply, companies can minimize upfront costs and eliminate the need to learn a new power source. The simplified process, seamless integration, and ability to revive older equipment make welding automation accessible and efficient. With the SmoothTool kit, businesses can harness the benefits of cobot welding, increase productivity, and stay competitive in the market. Currently, we support those using Euro connectors, but we will be expanding this list soon. Stay tuned to discover exciting upcoming news!

Watch our video to see how it works!

Explore our YouTube channel for additional videos, or visit the RetroFit Kit product page to discover more about the kit. If you have any further questions, please fill out the form on our contact page.