Lewis Welding factory has introduced collaborative robots within its new 120,000 square feet facility. There are two fixture stations that can accommodate 4-foot-long parts, placed at a 45-degree angle in front of the collaborative robots. PIPE EXHIBITION 2024 understands that with this setup, operators can easily load and secure pipe parts, allowing another collaborative robot to operate on the parts.

Additionally, the machine features "automatic welding" capabilities, which can sense material thickness and adjust the welding power accordingly, significantly reducing the operator's workload.

Operators recall feeling a bit nervous during the first encounter with the equipment during the welding process, having never seen it before, but within a few hours, they became proficient. The control software for the entire spot welding system is integrated with the collaborative robot controller, eliminating the need to learn two separate control interfaces, and the whole programming is designed to be user-friendly.

Currently, Lewis Welding uses the collaborative robots for only one task: the spot welding system has a built-in library that can be used for materials, welding caps, and thickness stacking. The factory states that previously, using the spot welder, an operator could only produce 100 parts per shift. With the collaborative robot spot welding system, approximately 140 parts per shift can be produced, and operators do not have to handle large parts.

The system also backs up a synchronized log of welding activities (welding positions, welding schedules, and power usage) that can be exported via the internet to emails. For customers needing process control and traceability, detailed data collection is very attractive.

PIPE EXHIBITION 2024 has learned that with the increase in automation, related issues have also arisen. The workshop needs to add an experienced automation engineer specializing in setting up and connecting collaborative robots and other machinery (such as press brakes). Thus, enterprises need to invest more in manpower but can also increase efficiency. During times of high workload, the engineer can allow three to four collaborative robots to operate together.

Due to the superior performance of collaborative robots, many manufacturers are undertaking similar initiatives.

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