Robotic welding has become the default choice for many manufacturers seeking consistent, repeatable weld operations. Whether you are replacing a manual welding operation or scaling existing production, it’s essential to select the right combination of robotic components.
A robotic welding solution comprises three core components: robotic arm, a welding tool, and weld-compatible robot programming software. You can purchase these components separately, as a fully combined solution, or somewhere in between.
For many buyers, the landscape of robotic welding solutions can be complex to navigate, especially if this will be your first robotic welding deployment.
This guide simplifies the decision-making process while you search for the right robotic welding system for you.
Robotic Welding Systems, Software, and Solutions — 5 Key Points Buyers Need to Know
Compared to simpler robotic applications, welding has some specific requirements that it’s important to remember.
While you are shopping for a welding solution, remember these 5 key points:
- Safety is Key — Welding operations are inherently hazardous, given they involve flaming torches, electrodes, or other potentially harmful tools. Even if you were using a robot model designed for collaborative use, welding cannot be collaborative and requires extra safety precautions.
- Budget for the Extras — The accessories required for safety and the welding process add extra cost to robotic deployments compared to simpler applications. Welding cells often cost 2 or 3 times than simpler robotic cells.
- Plan the Environment into Cell Design— Don’t overlook the extra deployment needs like ventilation for fume extraction. While you may already have these if you are automating an existing manual welding task, it’s important to include them in the robot cell design.
- Pick the Right Programming Software — Programming software can be a “make or break” factor for efficient robotic welding. By selecting the right robot programming software, you can significantly reduce the learning curve.
- Simplify Your Fixtures — In manual welding, humans can adapt to fixtures with awkward designs. Keep welding fixtures simple and accessible as overcomplicated designs can render an expensive robot setup unusable.
The Core Components of a Robotic Welding System
At their most basic, robotic welding systems have 5 main components:
| Component | Role | Key Buying Considerations |
|---|---|---|
| Industrial Robot Arm | Executes the weld trajectory | Payload, reach, repeatability, and programming ease. |
| Welding End Effector | Delivers the weld (MIG torch, laser head) | Robot compatibility, required accessories, and ease of maintenance. |
| Programming Software | Translates CAD geometry into robot welding motion | Ease of use, simulation capability, and multi-brand support. |
| Fixturing & Tooling | Holds the part in a precise, repeatable position | Accessibility for the welding tool. |
| Safety & Ventilation | Protects operators from fumes and hazards | Sensor integration, shielding, and airflow management. |
It’s common for buyers to focus a lot on the choice of robot and welding tool. However, the choice of software and fixture design often has more impact on the success of your robot welding solution.
Finding Top-Rated Robotic Welding Software for Precision Control
The right programming software can make a substantial difference to the effectiveness of your robot welding cell. You want to use software that has a proven track record for robotic welding.
When evaluating programming software, some critical features include:
- Offline programming and simulation — A good programming software will allow you to create and test your weld paths without stopping production. By optimizing your weld paths in simulation, you can cut deployment time significantly.
- Welding-specific path wizards — Dedicated tools for welding tasks are a must-have for quick and easy welding deployments. For example, the RoboDK Welding Add-in adds features for parametric welding, trajectory visualization, and command editing.
- CAD/CAM integration — Select a tool that supports your modeling software of choice, such as the RoboDK plugins for SolidWorks, Mastercam, and many more popular packages.
- Multi-brand robot support — A vendor-agnostic programming platform means you are not locked into one robot manufacturer’s ecosystem. This allows you to adapt your welding automation to your changing needs.
- Ease-of use — Welding professionals are not always robotics experts, but this shouldn’t be necessary. Pick a programming software that allows anyone to program the robot, even if they haven’t used robots before.
RoboDK is an ideal platform for robotic welding, with years of tested success in welding applications.
Where to Find Training Courses for Robotic Welding Programming
The global shortage of skilled welders is a well-documented problem across manufacturing industries. Robotic welding is a proven solution to overcoming this shortage, but it is often even harder to find welders with programming experience.
As you transition your welding processes to more robotic automation, you also need to train your welders to operate the robots.
Robotics training is therefore also a key consideration when you are purchasing any welding solution.
At RoboDK, we provide a range of training options for users looking to expand their robot programming skills for welding, from tutorials and webinars to full online courses.
Find out more in our article How to Reduce Training Time for Robot Welding
Making the Purchase Decision: What to Evaluate
Choosing the best robotic welding system isn’t just about picking the right manipulator. It’s about creating a streamlined welding process that both meets your current welding needs and is flexible for future changes.
Different welding processes often call for different robotic setups. As a result, your choice of solution will need to cater to your unique welding workflow.
By prioritizing intuitive programming — such as using RoboDK with our welding Add-ins — you can eliminate many of the common bottlenecks that stop manufacturers getting the most from their welding robots.
With the right welding solution, you can gain a swift return on investment, leading to long-term gains in weld consistency and throughput.
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