Welding steel frames with the Dobot cobot
Below you will find videos and photos showing what the entire process looks like, what the test results are, as well as key benefits and a description of the entire position.
Goals and challenges
The client needed a solution for welding steel frames (closed profiles). A key requirement was the ability to quickly redirect the machine to various dimensions of workpieces without the need to involve an industrial robot programmer.
Architecture of the site
Manipulator - Dobot CR10A
Cobot with a reach of 1300 mm and a payload capacity of 10 kg. Using the Drag&Drop function, the operator teaches the robot a path by physically guiding its arm.
Source - Kemppi Master M 358G
This is a premium unit with the Weld Assist function. It automatically selects welding parameters after entering the material thickness and weld type.
Control - Dedicated joystick
Allows you to precisely set points without taking your eyes off the detail.
See what the process looks like from learning the movement to welding
Process flow
-
Use the joystick or the drag and drop function to position the torch at the starting points.
-
System welding table with quick-clamping clamps to secure the profile.
-
Starts a program that performs continuous welding at a perfectly constant linear speed.
Burner setup and motion simulation
Welding
Securing the element and re-welding
Test results
Scale regularity
The cobot's constant feed rate provides aesthetics unattainable with manual welding in long series.
Process cleanliness
Thanks to the stable arc of the Kemppi Master M, spatter is reduced to a minimum, eliminating time-consuming post-weld grinding.
Geometry
The cobot's precision (0.03 mm) ensures that every frame is identical.
Key customer benefits
Short implementation time
Welding robots are easy to use, so an employee trained in using the station was able to
prepare a new program in a few minutes.
Easy to move
The station takes up little space (table 1220x800 mm) and can be easily moved with a forklift or on wheels
Save costs and time
Significant shortening of the production cycle while reducing gas and wire costs (no faulty welds).
The 6-axis DOBOT CR10A robot allows welding at almost any angle
Free consultation
Let's see how robots can really help your business.
We will advise you and answer all your questions, show you the possibilities, benefits and return on investment time in your specific case.
Will cobot welding of steel frames work for your company?
It's worth it It is worth emphasizing that thanks to the flexibility and short implementation time of cobots, the presented solution is not reserved exclusively for large plants or large-scale production.
A major advantage of the Dobot cobots we offer is that they can be easily adapted to weld new parts or change their dimensions. The operator can independently prepare a new path by guiding the robot arm, without complex programming or engaging an external specialist.
In practice, this means that a properly trained operator can independently prepare a program not only for one specific frame, but also for subsequent elements with different geometries.
The easily relocatable cobot station allows for smooth implementation and integration of the station with the infrastructure already present in the production plant, without unnecessary production downtime. Additionally, our cobots feature innovative technologies that allow for safe operation alongside humans - collision sensors, emergency stop systems, and operator presence detection systems are just some of the safety features used in our devices.
Welding structures with a cobot versus manual welding - what problems does a cobot solve?
Differences in steel structure production The differences between manual welding and cobot welding and the resulting benefits are clearly visible and have a real impact on saving time and money and ensuring consistently high, repeatable welding quality.
Repeatable welding quality regardless of batch size
In manual welding, weld quality depends on experience, concentration, and fatigue. In longer series, differences in the torch movement speed and angle may occur.
The cobot executes the saved welding path identically for each part. This means:
-
High level of precision that is unattainable with manual welding
-
This directly translates into the repeatable quality of each weld
-
Consistent parameters throughout the entire welding process
The problem with the availability of qualified welders
Many companies face a shortage of experienced welders on the labor market. In manual welding, quality largely depends on the operator's experience. The more difficult the weld and the longer the series, the more important experience becomes.
When we implement a welding robot into the process, it provides the following benefits:
-
Even a less experienced employee can maintain repeatable quality
-
Work efficiency is maintained at a high level
-
Reduced risk of downtime and delays caused by temporary unavailability of highly qualified workers
Reducing the risk of rework due to worker fatigue
In long and repetitive welds, fatigue has a real impact on the speed of the torch and the quality of the work. The cobot follows the programmed path in the same way 24 hours a day, helping to reduce errors, material waste, and the need for additional rework.
Improved occupational safety
Welding involves high temperatures, spatter, and fumes generated during operation. In manual welding, the operator is constantly directly at the weld site. In a cobot-style workstation, the robot guides the torch, while the employee supervises the process and prepares subsequent components. This reduces the need to be directly at the welding arc and streamlines the workflow at the workstation. This demonstrates that a welding cobot is a solution that not only increases efficiency but also significantly relieves the employee of the most demanding part of the process. In companies that prioritize the health and safety of their team, this is a key factor when deciding whether to implement collaborative robots.
What does changeover look like when welding structures? robot
One of the most common questions regarding robotization of the welding process is retooling and programming for new elements. We design our welding stations to make the changeover process as easy and efficient as possible.
At this station, changeover involves:
-
changing the mounting on the welding table,
-
setting new starting points using a dedicated joystick or arm guidance,
-
starting motion simulation
A well-designed station allows a trained operator to prepare a new variant in just a few minutes. It does not require the involvement of an external programmer. If you have any questions, we are in constant contact with our customers and are happy to assist you with automation and robotics.
FAQ - questions and answers regarding robotic welding of steel structures and frames
Does the robot require regular servicing?
The Dobot cobots we offer do not require classic, cyclical maintenance activities associated with traditional mechanics, such as lubrication, belt replacement, etc.
What if the cobot fails?
We act quickly and specifically - we diagnose and replace the specific component that is actually causing the problem. With our robots, it's possible to very precisely diagnose the specific part that's causing the problem, which in most cases eliminates the need for costly replacements, large parts assemblies, and replacing an entire joint is usually a last resort.
If the robot cannot be repaired and returned to working order within 7 days, we will provide a new robot, which will be sent to you, and the existing one will be sent to the service center for a thorough diagnosis and repair.
What is the availability of spare parts for repairs?
All robot components are available from warehouses in Germany, so delivery and replacement are usually next day.
What is the warranty for this robot?
The standard warranty is one year + 6 months for commissioning and implementing the robot. There is an option to extend the warranty to a total of 5 years for an additional fee.
Can the robot be used for other applications or the station expanded in the future?
If, for any reason, we need to use the cobot for a different task, e.g., assembly, this is absolutely possible (of course, if we change the attachment, such as a gripper instead of a torch, etc.). The prepared cobot station can be a starting point for further automation – both in the area of welding other elements and robotization of production processes of a different type.
Can a cobot weld more complex elements and structures?
It not only enables, but in many cases actually facilitates, welding more complex structures.
Thanks to its 6 axes of movement, the cobot can position the torch at the required angle and maintain this position stably throughout the entire length of the weld. When welding manually, maintaining a constant angle and speed at difficult angles can be challenging – especially over longer welds.