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, Hirebotics, Vectis Automation, Wecobot, and more

Global Cobot Market Share: 33,60 %

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: 14,30 %

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: 11,50 %

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: 2,80 %

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: 4,20 %

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.

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.

Think of cladding like putting a protective coat on a metal surface, but instead of paint, we’re using another metal with special properties. The process involves depositing a layer of filler metal onto a base metal (also called the substrate) to give the surface new characteristics while keeping the structural strength of the base metal underneath.

To understand why we use cladding, imagine you have a large steel structure that needs to resist corrosion. Instead of making the entire structure from expensive corrosion-resistant metal, you can use regular carbon steel and clad just the surface with a corrosion-resistant metal like stainless steel. This gives you the best of both worlds: the strength and cost-effectiveness of carbon steel with the corrosion resistance of stainless steel.

Cladding vs Hardfacing

Cladding and hardfacing are often confused with one another. While both techniques fall under the umbrella of surfacing, let us examine the key differences between cladding and hardfacing.

Cladding focuses on corrosion resistance. We apply a layer of corrosion-resistant material (like stainless steel or nickel alloys) over a base metal to protect it from chemical attack. The process requires careful control of dilution between the metals to maintain corrosion resistance, and the goal is to create a smooth, continuous protective layer.

Hardfacing, in contrast, is about wear resistance. We deposit hard, wear-resistant alloys onto areas that experience heavy abrasion or impact. The surface doesn’t need to be as smooth as with cladding, and we often apply it in patterns to help manage wear. The focus is on creating a hard surface that can withstand physical abuse rather than chemical attack.

Examples of use

The real beauty of cladding lies in its versatility. You can select different cladding materials based on what properties you need: corrosion resistance, heat resistance, or even special electrical properties. It’s like giving your metal surface a superpower, but only where you need it.

Oil and gas industry

Storage tanks and pipelines face constant exposure to corrosive substances. For example, a crude oil storage tank in Saudi Arabia might need to hold millions of gallons of oil containing corrosive sulfur compounds. Rather than building the entire tank from expensive corrosion-resistant alloys, engineers use carbon steel for structural strength and clad the interior with a 3-5mm layer of stainless steel using submerged arc welding. This cladding protects against corrosion while keeping construction costs manageable.

Chemical processing

Consider pressure vessels in chemical processing plants that need to maintain integrity while handling corrosive materials. Robotic GMAW systems can precisely deposit layers of high alloy material onto carbon steel vessels. The robot’s consistent travel speed and wire feed rate ensure uniform penetration and minimal dilution, creating a high-quality corrosion-resistant layer that protects the underlying structure. This is particularly valuable in areas where manual welding would be difficult, such as the interior curves of vessels or hard-to-reach corners.

Water Treatment

In desalination plants, seawater handling equipment faces constant exposure to chlorides. Consider a large heat exchanger tube sheet made of carbon steel. Automated welding systems can systematically clad the surface with high nickel alloys like Inconel 625. The robot’s precise control allows for overlapping weld beads with consistent 30-40% overlap, creating a continuous corrosion barrier. The automated process maintains exact wire feed speeds and voltage parameters, crucial for achieving the right chemistry in the final deposit.

Offshore

Offshore platforms face particularly challenging conditions where seawater meets hydrocarbons. The risers (pipes that transport oil from the seabed to the platform) experience both internal and external corrosion threats. These components are often manufactured with a carbon steel base and are then clad with Inconel 625 using automated arc welding. This combination provides the necessary strength to handle high pressures while protecting against corrosive fluids.

The cladding process

The cladding process follows a series of key steps that must be executed with precision to achieve optimal results. Each stage plays a critical role in ensuring the quality and reliability of the final protective layer.

1. Surface Preparation: The base metal must be thoroughly cleaned to remove any contaminants that could affect the quality of the cladding. This includes removing rust, scale, oils, and other debris to ensure a clean surface for bonding.
2. Equipment Setup: The welding equipment needs proper setup with corrosion-resistant wire and appropriate shielding gas. The specific settings for voltage and wire feed speed are determined by the materials being used and the application requirements.
3. Preheating: Preheating the base metal helps ensure proper fusion between the base metal and the cladding material. This step is essential for achieving a strong metallurgical bond.
4. Cladding Application: The actual cladding begins with laying down the first layer using a weaving pattern. The welder maintains consistent movement and overlap between passes to ensure complete coverage of the surface.
5. Intermediate Cleaning: Between layers, cleaning is essential to maintain the quality of the cladding. This removes any residue that could affect the next layer’s bonding.
6. Layering and Temperature Control: Additional layers may be added depending on the required thickness and specifications. Temperature control remains important throughout this process to ensure proper fusion and prevent defects. Proper fusion and temperature control can also involve keeping the temperature low. This can be achieved by applying water cooling to the backside and using modified arcs (e.g., EWM React), which ensure focused penetration with low heat input. This approach minimizes excessive mixing of the base material (carbon), typically keeping the base material dilution below 2%. Achieving dilution levels under 1% significantly extends the lifespan of the cladding layer, resulting in substantial financial and environmental savings. However, achieving dilution under 0.6% is impossible due to the carbon content inherent in the wire.
7. Final Inspection: The process concludes with a thorough inspection to verify the quality and completeness of the cladding. This step involves checking for proper coverage and identifying any potential defects.

By adhering to these steps, the cladding process ensures a high-quality protective layer that can withstand rigorous conditions. This meticulous approach not only enhances the structural integrity of the base material but also contributes to improved performance and reliability in its intended application.

Cladding Wire Types

In cladding applications, the choice of wire is crucial to ensure proper bonding and durability. Here are common types of wires specifically used for cladding, not hardfacing:

1. Nickel-based Wires
   • Examples: ERNiCrMo-3, ERNiCu-7
   • Applications: Commonly used for corrosion-resistant cladding in industries such as oil and gas, chemical processing, and marine environments.
2. Stainless Steel Wires
   • Examples: ER309L, ER316L, ER347
   • Applications: Ideal for cladding carbon or low-alloy steels to provide resistance to corrosion and oxidation in high-temperature environments.
3. Aluminum Wires
   • Examples: ER4045, ER5356
   • Applications: Used for cladding aluminum alloys or when weight and corrosion resistance are critical, such as in aerospace and transportation.
4. Inconel Wires
   • Examples: ER625, ER725
   • Applications: These nickel-chromium alloy wires are highly resistant to oxidation and corrosion, making them suitable for cladding in extreme environments, such as offshore and subsea applications.

Each wire type is selected based on the base metal, service conditions, and the desired properties of the cladded surface. Proper wire selection ensures compatibility and optimal performance in the intended application.

Cladding and Robotic Welding

Manual cladding is a labor-intensive and time-consuming process that requires a high level of skill and concentration. Achieving consistent quality across large or complex surfaces is challenging, as human operators are prone to fatigue, variability in technique, and errors. These issues can lead to uneven coverage, poor fusion, and increased rework, compromising the effectiveness of the cladding layer.

Robotic welding, particularly collaborative robot (cobot) welding, addresses these pain points by delivering unparalleled consistency and precision. Robots can maintain uniform movement and overlap, ensuring even coverage and strong bonding throughout the process. Cobots, which are designed to work safely alongside human operators, add flexibility to the process by combining human expertise with robotic accuracy.

Additionally, robotic systems excel in maintaining critical parameters such as temperature, wire feed speed, and travel speed, which are essential for preventing defects. Their ability to handle repetitive tasks without fatigue results in higher productivity and more reliable cladding outcomes, making them an ideal solution for industries demanding superior performance and durability from their materials.

Cladding with SmoothTool’s New Surfacing Feature

With our software’s new surfacing feature, you can easily define complex cladding patterns and optimize your process for maximum efficiency. How it works:

1. Choose the Surfacing template
2. Choose between Flat or Curved surface type
3. For Curved: Select weld direction; Along or Across
4. Teach the first pass and offset direction
5. Enter desired number of passes and adjust parameters

Key Benefits of Cobot Cladding with SmoothTool:

• Enhanced Productivity: Achieve higher arc-on time and consistent weld quality.
• Improved Worker Safety: Eliminate exposure to hazardous fumes and physical strain.
• Reduced Costs: Lower labor expenses and minimize material waste.
• Ensured Quality: Maintain precise control over the cladding process.
• Simplified Programming: Quickly and easily create complex cladding patterns.

Don’t let manual cladding limit your potential. Embrace the future of surface enhancement with cobot welding and SmoothTool.

What is hardfacing?

Hardfacing is a technique used to make metal surfaces stronger and more resistant to wear and tear.

It involves applying a layer of a harder, more durable material on top of a softer metal. This is done by welding the hard material onto the surface, creating a protective layer that can handle more abrasion, impact, or heat than the original metal.

It’s commonly used on parts that experience a lot of friction, like tools, machinery parts, or equipment in mining and agriculture, to help them last longer and perform better.

There are several welding methods for hardfacing, including stick welding, submerged arc welding (SAW), laser welding, and TIG welding. However, MIG/GMAW (Metal Inert Gas / Gas Metal Arc Welding) is often the preferred choice for on-site hardfacing of large objects. MIG/GMAW stands out in these situations because it is fast, flexible, and produces a smooth, consistent layer. Additionally, it is easier to control, especially on larger surfaces, and allows for continuous welding with minimal stops, making it efficient for high-wear applications.

Hardfacing vs Cladding

Hardfacing and Cladding are often confused with one another. While both techniques fall under the umbrella of surfacing, let us examine the key differences between cladding and hardfacing.

Hardfacing, in contrast, is about wear resistance. We deposit hard, wear-resistant alloys onto areas that experience heavy abrasion or impact. The surface doesn’t need to be as smooth as with cladding, and we often apply it in patterns to help manage wear. The focus is on creating a hard surface that can withstand physical abuse rather than chemical attack.

Cladding focuses on corrosion resistance. We apply a layer of corrosion-resistant material (like stainless steel or nickel alloys) over a base metal to protect it from chemical attack. The process requires careful control of dilution between the metals to maintain corrosion resistance, and the goal is to create a smooth, continuous protective layer.

Examples of use

Hardfacing is a versatile technique used across various industries to enhance the durability and lifespan of metal components by applying a wear-resistant layer. Here are some tangible real-life use cases for hardfacing:

Agriculture

Plowshares and Tillage Tools: In remote locations where replacement parts are hard to get, hardfacing is applied to plowshares and tillage tools to resist abrasion from soil and rocks, extending their service life significantly.

Harvesting Equipment: Components such as cutter bars and threshing drums benefit from hardfacing to withstand the abrasive nature of crops and soil.

Mining

Crusher Jaws: Hardfacing is used on crusher jaws to enhance resistance against the impact and abrasion from crushing rocks and ores, thereby reducing downtime and maintenance costs.

Earthmoving Equipment: Buckets, blades, and other parts of excavators and loaders are hardfaced to endure the harsh conditions of mining operations.

Construction

Excavator Buckets: Hardfacing strengthens excavator buckets against wear from digging and moving materials like gravel, sand, and rocks.

Asphalt Paving Equipment: Augers and hoppers in asphalt paving machines are hardfaced to resist wear from hot, abrasive materials.

Forestry

Debarking Equipment: Hardfacing is applied to debarking equipment to combat the abrasive action of bark mixed with sand and other materials.

Saw Blades: Hardfacing extends the life of saw blades used in cutting timber by providing a hard, wear-resistant edge.

Manufacturing

Brick Manufacturing Equipment: Machines involved in brick production are hardfaced to handle the abrasive nature of clay and other raw materials.

Pulp and Paper Industry: Equipment like chippers and grinders are hardfaced to resist wear from processing wood chips into pulp.

Energy Sector

Coal Crushing Equipment: Hardfacing is used on coal crushers to withstand the abrasive nature of coal mixed with silica or sand.

Hydroelectric Turbines: Turbine blades are clad with hardfacing materials to resist erosion from water flow.

These examples illustrate how hardfacing enhances the performance and longevity of equipment across various sectors by providing a durable, wear-resistant surface that minimizes maintenance costs and downtime.

Hardfacing with GMAW welding

Hardfacing using Gas Metal Arc Welding (GMAW), or MIG welding, involves several key steps to ensure a successful application. Below is a detailed explanation of the process:

1. Preparation

• Surface Cleaning: The surface of the workpiece must be thoroughly cleaned to remove any dirt, grease, rust, or other contaminants. This is crucial to prevent weld defects and ensure a strong bond between the base metal and the hardfacing material.
• Preheating: Depending on the base material, preheating may be necessary to reduce thermal shock and prevent cracking during welding.

2. Selection of Materials

• Hardfacing Wire: Choose a suitable hardfacing wire based on the desired properties such as wear resistance, hardness, and impact resistance. Common materials include iron-based, nickel-based, and cobalt-based alloys.
• Shielding Gas: Use an appropriate shielding gas to protect the weld pool from atmospheric contamination. Pure argon or argon mixtures with oxygen or carbon dioxide are commonly used to achieve low penetration and dilution.

3. Welding Process

• Machine Setup: Set up a MIG welding machine. Adjust parameters such as voltage, amperage, and wire feed speed according to the manufacturer’s recommendations for the specific hardfacing wire.
• Welding Technique: Employ a consistent welding technique to ensure even deposition of the hardfacing material. The process involves creating an electric arc between the consumable wire electrode and the workpiece, which melts both materials and allows them to fuse together.

4. Application

• Layer Deposition: Apply one or more layers of hardfacing material to achieve the desired thickness and properties. The thickness can range from 1 to 10 mm depending on the application requirements.

Hardfacing Wire Types

Specialized hardfacing wires are typically used for applications requiring high wear resistance. These wires are designed to deposit a hard, abrasion-resistant layer on the surface of a workpiece.

Iron-based Alloys

Iron-based hardfacing wires are commonly used due to their versatility and cost-effectiveness. These wires often contain:

• High chromium content (typically 20-30%)
• High carbon content (3-5%)
• Other alloying elements like manganese, silicon, and sometimes molybdenum

The high chromium and carbon content form hard chromium carbides, which provide excellent abrasion resistance.

Cobalt-based Alloys

Cobalt-based hardfacing wires are used for extreme wear resistance, especially at high temperatures. These alloys typically contain:

• Chromium
• Tungsten
• Carbon

The cobalt matrix provides excellent hot hardness, while the chromium and tungsten form hard carbides for wear resistance.

Reasons for Material Selection

1. Chromium: Forms hard carbides, enhancing abrasion resistance

2. Carbon: Combines with chromium to form carbides, increasing hardness

3. Manganese: Improves toughness and work-hardening properties

4. Silicon: Acts as a deoxidizer and improves fluidity of the weld pool

5. Molybdenum: Enhances high-temperature strength and wear resistance

The specific composition of hardfacing wires is tailored to the intended application, balancing factors such as abrasion resistance, impact resistance, and operating temperature.

Hardfacing and Robotic Welding

Hardfacing is an excellent fit for robotic welding because it is a tough job to do manually.

Hardfacing is a time-intensive and monotonous process that is physically demanding and requires significant focus. The extreme heat, fumes, and repetitive nature of the work take a heavy toll on welders, both mentally and physically.

Robots eliminate these challenges by doing the work without breaks, maintaining precision, and ensuring consistent quality. They can handle high heat and repetitive tasks without fatigue, making the process more efficient and safer while delivering better results.

Using robots for hardfacing improves productivity, reduces errors, and protects human workers from a demanding and exhausting job.

Hardfacing with SmoothTool’s New Surfacing Feature

With our software’s new surfacing feature, you can easily define complex hardfacing patterns and optimize your process for maximum efficiency. How it works:

1. Choose the Surfacing template
2. Choose between Flat or Curved surface type
3. For Flat: Teach the outline and the welding direction
4. Select if you want to weld the outline and enter the number of welds to infill with
5. Fine tune your other surfacing settings and the power source parameters

Key Benefits of Cobot Hardfacing with SmoothTool:

• Enhanced Productivity: Achieve higher arc-on time and consistent weld quality.
• Improved Worker Safety: Eliminate exposure to hazardous fumes and physical strain.
• Reduced Costs: Lower labor expenses and minimize material waste.
• Ensured Quality: Maintain precise control over the hardfacing process.
• Simplified Programming: Quickly and easily create complex hardfacing patterns.

Don’t let manual hardfacing limit your potential. Embrace the future of surface enhancement with cobot welding and SmoothTool.

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.

Table of Contents

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!

What are the Welding Requirements?

The first thing you need to think about is what kind of welding you need to do. This will determine the type of robot, the welding process, the power source, and the consumables you will need. Some of the aspects to consider are:

• Material: What kind of metal are you welding? Different metals have different properties and require different welding methods and parameters. For example, steel is more commonly welded with gas metal arc welding (GMAW) or flux-cored arc welding (FCAW), while aluminum is more suitable for gas tungsten arc welding (GTAW) or pulsed GMAW.
• Volume: How many pieces do you need to weld per day, week, or month? This will affect the speed and reliability of your robotic welding system. Higher volume means higher duty cycle and higher throughput. You will also need to consider the availability of spare parts and consumables, as well as the maintenance and downtime costs.
• Mix: How many different types of parts do you need to weld? This will influence the flexibility and versatility of your robotic welding system. Higher mix means more frequent changeovers and more complex programming. You will also need to consider the storage and handling of different fixtures and tools, as well as the quality control and inspection procedures.
• Size: How big are the parts you need to weld? This will impact the size and reach of your robot, as well as the space and safety requirements of your work cell. Larger parts mean larger robots and larger work envelopes. You will also need to consider the weight and balance of the parts, as well as the transportation and loading methods.
• Consistency: How uniform are the weld seams you need to produce? This will affect the accuracy and repeatability of your robotic welding system. Higher consistency means higher quality and lower rework. You will also need to consider the tolerance and variation of the parts, as well as the calibration and alignment procedures.

Types of Robotic Welding Systems

Once you have defined your welding requirements, you can start looking at the different types of robotic welding systems available on the market. There are two main categories: traditional industrial robots and collaborative robots (or cobots).

Traditional industrial robots are large, powerful and fast machines that can handle high-volume, low-mix and consistent welding tasks. They require a dedicated work cell with safety fences, sensors and interlocks to protect humans from potential hazards. They also require skilled programmers and operators to set up, run and maintain them.

Collaborative robots (or cobots) are smaller, lighter and slower machines that can handle low-volume, high-mix and variable welding tasks. They can work alongside humans in a shared space without safety barriers, thanks to their built-in sensors and force limiters that prevent them from causing harm. They also require minimal programming and training to operate them.

One of the advantages of cobot welding is that it can leverage your existing manual welding skills and equipment. With SmoothTool from Smooth Robotics, you can easily convert any manual power source into a robotic power source by using the RetroFit kit from Smooth Robotics. This way, you can save money on buying a new power source and use your existing one with a cobot.

Code or No-code

Another factor to consider when choosing a robotic welding system is how easy it is to program it. Traditional industrial robots require complex code-based programming that involves writing lines of code or using a teach pendant to manually move the robot along the desired path. This can be time-consuming, error-prone, and difficult to modify.

Cobot welding offers user-friendly no-code programming options and the ability to physically teach the robot welding paths. This can be faster, easier and more intuitive to use and eliminates the need for a dedicated robot programmer.

SmoothTool from Smooth Robotics is a great example of a no-code cobot welding solution that allows you to program your cobot in minutes without any prior experience. You simply go through these 4 steps in order to program a weld:

1. Set approach point(s)
2. Set weld start point
3. Set weld path point(s)
4. Set exit point(s)

Then you have a program ready to be run as is or expanded with features such as weaving patterns, stitch welding, angle correction, or another of the many SmoothTool features.

What Power Source to Use

What kind of power source do you need to use for your welding process? Different power sources have different features and capabilities that can affect your welding performance and quality. For example, some power sources can offer advanced functions such as pulse control, waveform control, arc force control or hot start control that can improve your weld penetration, appearance, spatter reduction or arc stability.

Opting for traditional industrial robots for welding tasks will require you to invest in a sophisticated robotic power source. Most of the time, this power source will be included in the complete package, which makes these robotic welding systems more expensive.

Unlike traditional welding techniques, Cobot welding with SmoothTool enables you to utilize any power source, including your current manual power source, with the help of the RetroFit Kit developed by Smooth Robotics. This is a cost-effective method for initiating robotic welding.

Making the Right Choice

When it comes to selecting a robotic welding system for your business, there are several factors that you need to consider. You should carefully evaluate your welding requirements, the various types of robotic welding systems available, the programming options and your budget to make the best decision for your specific needs.

If you are still unsure about which robotic welding system is right for you, or if you are interested in learning more about Smooth Robotics’ SmoothTool cobot welding solution, we would like to invite you to contact us for a free consultation. Our team will be delighted to answer any questions you may have and demonstrate how our cobot welding solution can help you enhance your welding performance and profitability.