ABOUT US  |  BLOG

welding automation system types

Welding Automation for YOUR Business

Finding the Right Tool for the Job – Welding Automation Types

  

On the fence about whether welding automation can actually work—AND be profitable—for your business and project applications? We realize how imperative it is to get answers upfront to all your automation questions. We’ve put together this comprehensive guide to help you through the basics.

Automaton Works to:

  • Improve weld quality
  • Enhance safety and the overall well-being of operators
  • Increase productivity
  • Attract skilled workers
  • Lower ongoing costs
  • Grow your bottom line
Welding Automation Types

3 Needs to Move Forward in Automation

 

1. Workpiece Uniformity

Why is uniformity SO critical?

All automation or semi-automatic welding equipment is programmed on a “master part,” meaning the welding path and framework is set and then repeated over and over.  When the part location or welding condition changes, the automated equipment will not know without adjustments made by the operator.  Therefore, part uniformity is one of the most important aspects of any automated process.  One of the best ways to improve inconsistencies is to address the source!

Quality and consistency through repeatability is the most predominant perk to welding automation.

 

2. Opportunity

If you’re under the impression that you need a complex or large-scale weldment in order to make automation worthwhile, think again. We’ve noticed many shops experience huge gains from automating simple or small parts. This strategy allows for automation to do what it does best on the simplistic parts and gives your skilled welders time to focus on more complicated projects.

 

3. The Right Team

We talk a lot about teaming up with a reputable welding automation partner or integrator. Along with an experienced team like Bancroft Engineering, the most successful long-term automation gains come from teams of operators who have a high level of ownership and are willing to problem solve to get the job done right.

  

3 Types of Welding Automation

Having a full understanding of the automated welding solutions available, along with their benefits and drawbacks, is the first step to making the right choice for your needs. Here are the three main types of welding automation:

Fixed Automation

Fixed welding automation equipment is built and designed to weld a specific part or part-family. This is one of the most cost-effective forms of automation. A few examples of fixed automation systems include linear welders,  rotary welders and circle welders, seam welders and circumferential welders.  This solution is best for high volume parts.

robotic welding machines

Robotic Welding

Traditional robotic welding is what most think of when it comes to welding automation. Robots come in all sizes and are offered by robot manufacturers, suppliers, and integrators. Robots require a certain set of safety equipment to protect humans such as guarding, fences and sensors. The best fits for robotic welding are large parts, complicated welding, and high-volume operations.

collaborative welding automation

Collaborative Automation

One of the newest forms of automation is collaborative technology. Collaborative robots include internal sensors, allowing humans to work directly with the robot in the same space. This eliminates the need for safety fences and frees up more shop floor space. Collaborative welding automation is best for low volume production and for those needing a lot of flexibility.

With over 50 years of welding equipment experience, Bancroft Engineering has worked to improve automated welding processes for hundreds of businesses. We’re always ready for your specific application questions—get in touch with our engineers today!

Read More
welding machine section 179 tax deduction

Using Section 179 Tax Deductions for a Welding Machine in 2020

Whether you’re buying a new machine for the first time or are ready to upgrade existing equipment, the Section 179 tax deduction is something you’ll want to look into. When you purchase automated welding equipment from Bancroft Engineering, you will not only be improving your manufacturing process but also saving your business money on your 2020 taxes with Section 179 expensing.

 

How Does Section 179 Expensing Work for Welding Equipment Purchases?

The Section 179 Tax deduction is for all businesses that purchase (or finance) new and used business equipment during the 2020 tax year.

Section 179 of the United States Internal Revenue Code (26 U.S.C. § 179) is now available which allows you to write-off up to $1,040,000 of a qualifying equipment purchase for 2020. This annual deduction amount is up from $1,000,000 in 2019.

In past years, when manufacturers purchased welding equipment, they would write it off little by little through depreciation. For example, if your business spent $80,000 on a piece of machinery, you might write off $20,000 per year for five years.

When you use Section 179 in 2020, a business can write-off the entire purchase price of qualified equipment for the current tax year. As in our previous example, if your business spends $80,000 on a piece of automated welding machinery, you can write off all $80,000 in the same tax year using Section 179. This is an attractive tax deduction for small and mid-sized businesses to take advantage of!

How to Qualify for Section 179 in 2020

If you’re considering whether or not to purchase new equipment this year, section 179 is an attractive tax deduction to take into consideration. It’s also easy to understand and apply. Most new and used tangible business equipment qualifies as long as it meets the following criteria:

  • Equipment must be installed and ready for service in the same tax year
  • More than 50% of the use of the equipment must be used for business

Real Example of Section 179 Expensing in 2020

  • Cost of equipment after Bancroft Engineering discounts: $200,000.00
  • Section 179 Deduction: $200,000.00
  • Total First Year Deduction: $200,000.00
  • 35% Saving on Equipment Purchase: $70,000.00
  • Lowered Cost of Equipment After Tax Savings: $130,000.00
automated welding systems tax savings 2020
Image by: aws.org

NEW Automated Welding Machines + Tax Savings 

Buying equipment or upgrading your existing welding machines can provide many benefits from improved quality, increased production to better staff morale. Thankfully, these tax breaks allow you to afford the equipment you need!

Bancroft Engineering designs and builds welding equipment such as standardized and custom welding machines and much more out of Waukesha, WI—specializing in stand-alone equipment to fully robotic automated systems. Need help automated your welding process or have a special welding application? Give us a call at 262-786-1880, or email: sales@bancrofteng.com to get started.

Read More

A Guide to Optimal Robotic & Automated Welding

Getting Started with Automated Welding Systems

 

Automated welding is the way many manufacturers are fabricating these days. With that, there are a lot of misconceptions about how easy automated systems are to use and if the benefits outweigh the struggles.

Automatic welding has a host of clear perks such as improved weld quality, faster cycle times, and a better working environment for welders. A common restriction is that robots require a certain skillset to program and run the equipment smoothly. Don’t worry, the technology has advanced greatly, leading to simple ways to accomplish quality automated welding without the hassle.

We’ve unpacked the most optimal process for getting started with automated welding systems so you can benefit from high-quality welding with less stress!

  

1. Define Welding Type & Tasks

With any welding project, you’ll need to first define and understand the task at hand.  What type of welding will be needed? Which steps will the robot or automated welding machine need to perform? There are a variety of different welding types—below are some of the most common:

  • Circumferential (Rotary) welding
  • Linear (Seam) welding
  • Resistance (Spot) welding

The technical specialists at Bancroft Engineering can help you confidently define the scope of your welding project and automated system requirements so your job will be successful—get in touch with us.

2. Secure the Needed Equipment

Now that you’ve clearly defined the task and welding type needed, it’s time to pick the right automated welding system—whether that be a robot or semi-automated welding machine. Most welding systems require the following pieces of hardware/software:

  • The robot or the welding machine itself
  • The welding tools & fixtures
  • A user-friendly programming interface
  • Welding power supply and consumables
  • Safety measures such as barriers or sensors
automated welding machine
Universal Welding Robot

3. Determine Proper Weld Settings

There are basic guidelines for picking weld settings, but they can vary from model to model and certainly from brand to brand.  To get to the best weld setting, a number of considerations must be made including:

  • Type of metal you are welding
  • Cleanliness of the joint
  • Joint design
  • Material thickness
  • Proper wire size
  • Voltage
  • Wire feed speed
  • Travel speed
  • Torch position
  • Shielding gas

This can seemingly be a daunting task, but any good welding equipment manufacturer will have engineers on staff to assist with this process.

semi automated welding postioner
TT500 Welding Positioner

4. Program, Test, & Debug

Programming an automated welding machine requires a trained specialist for the initial start-up.  This only needs to be done upon setting up your system for the first time.  General maintenance programs and welding schedules can be created and modified with little training throughout the lifestyle of the system.

Once your system is in place and programmed correctly, it’s time to sit back and watch the system make magic happen!

 

5. Team Up with the Right Automated Welding Provider

Lastly, team up with a reputable welding automation provider who can walk with you every step of the way. From concept to installation and run-off, the team at Bancroft Engineering is here to ensure your new welding system is successful!

 

Bancroft offers both customized welding machines and a variety of standardized semi-automatic welding equipment in stock such as positioners, Welda-Round rotary welders, seam welders, weld-lathes and much more!

Read More
GMAW welding nozzle automated welder

How to Choose the Right GMAW Nozzle

Choosing equipment that provides the highest weld quality goes all the way down to the fine detail. The right welding nozzles—or contact tip—make a significate difference between running an efficient and productive shop or dealing with downtime to address problems. Gas metal arc welding (GMAW) guns have a variety of welding nozzle designs and styles to choose from—making it tricky to choose the right nozzle for your weld process.

The welding experts at Bancroft Engineering know a thing or two about optimizing all different types of welding processes—from small to large scale parts to automated welding systems. Let’s get into the common nozzle materials, designs and features so you can be equipped to make the best choice.

 

About Weld Nozzles 

The main purpose of a welding nozzle is to direct the shielding gas into the weld puddle in the best way possible. When selecting the right GMAW nozzle, you’ll need to keep in mind your welding application and joint access as some designs offer better gas coverage, while others allow better access.

Welding Nozzle Materials

The two most common materials used for welding nozzles are either copper or brass. Copper tends to be a better choice for overall spatter resistance, they also manage heat well at higher temperatures. Brass welding nozzles also have good spatter-resistant properties, but only in lower-amperage applications. Nickle-plated welding nozzles are also available and provide improved durability. Nickle is able to deflect heat, keeping the nozzle cool while welding. This allows for a longer life span and often is a preferred choice for robotic welding applications.

 

Weld Nozzle Shapes and Designs

Nozzle shapes include straight, bottleneck and short/long tapper styles. A straight welding nozzle usually has a larger inside diameter, but don’t offer the best joint access. If joint access is needed, a bottleneck nozzle is a better option. Bottleneck shapes are especially good for automated welding systems. Both short and long taper nozzles are also a common choice for achieving good joint access. When selecting your nozzle shape, keep in mind you’ll want to allow for the proper amount of gas to flow to the weld puddle. It’s best to use as large of a nozzle as possible that still allows easy access to the weld joint. This will ensure the greatest shielding gas flow and keep spatter to a minimum.

Threaded Welding Nozzle
Threaded Welding Nozzle
slip-on welding nozzle
Slip-on Welding Nozzle

Threaded vs. Slip-On Nozzles

The main distinction between threaded and slip-on welding nozzles comes down to speed and security of the connection. Threaded nozzles have a secure connection to the welding torch, preventing shielding gas leaks. This also helps align the contact tip correctly so the nozzle will not be off-center. A down-side to threaded nozzles is that they can be difficult to remove and replace—especially if spatter bridges into the threads. Slip-on welding nozzles are easy to remove and replace and are typically more cost-effective than treaded nozzles. Slip-on nozzles are ideal for welding applications that produce more spatter because their design protects the other welding consumables.

 

Custom Welding Equipment Builders & Welding Nozzle Experts

Weld gun nozzles play a critical role in your overall welding operation. Choosing the proper nozzle for the job will reduce welding defects, rework and downtime—this ultimately shows up in your bottom line!  Bancroft Engineering is a leading supplier of custom welding equipment for manual, semi-automatic to fully automated welding systems located in WI, USA.  Give us a call today at 262-786-1880 or email: sales@bancrofteng.com

Read More
welding positioners WI

What to Know About Welding Positioners

Photo above: NEW TT530 Automated Positioner

Utilizing welding positioners can expand a fabricator’s opportunities for both productivity and profits. Bancroft Engineering specializes in both manual welding positioners and semi-automated positioners for welding.  Let’s get into the benefits of using positioners and what you should know.

What are Welding Positioners?

A welding positioner is a mechanical piece of equipment that holds and rotates a workpiece to allow a welder to work at a proper angle and on a consistent surface. It has the ability to rotate a fast speed, even when bearing significate weight.  The main purpose of a welding positioner is to ensure the workpiece is ALWAYS in the most suitable welding position.

Positioners Increase Welding Throughput

Positioners improve productivity because they remove wasted time in multiple aspects. First of all, welding positioners ensure maximum arc time. Cranes, chains, grippers and other types of rigging equipment take a lot of effort to move and oftentimes, welders are left waiting around for the workpiece to be positioned correctly—this may have to happen multiple times for one weldment.

The use of positioners also allows the welder to manipulate the part quickly! When it comes to large parts, positioners allow one operator to handle the job, removing multiple people to reposition the part. This shows up in labor savings and frees up employees to perform other work.

Positioners Improve Weld Quality

A major advantage of using the right welding positioner is that it yields consistent, high-quality welds. Any movement of the part during the welding process makes it difficult to produce quality welds. When your material is secured, it allows for adequate weld penetration and it also makes it easier to run complete welds without the interruption of repositioning. A welding positioner solves many problems when it comes to weld quality as it rotates the workpiece at a controlled rate and speed to maintain a continuous, penetrative weld.

semi automatic welding positioner

Retrain & Attract Skilled Welders 

With the current welding workforce being slim, retaining and attracting skilled welders is a huge benefit to any manufacturer. Positioners allow welders to work faster, longer and with more ease. This equipment improves the working environment—making it much more attractive to a skilled workforce.  Welding positioners also:

  • Enhance safety
  • Allow both skilled and entry-level welders to make high-quality rotary welds
  • Improve employee morale
  • Use semi-automatic functioning to limit worker fatigue and increase production speeds

Premier Welding Positioners Available

The line of multi-axis welding positioners by Bancroft Engineering provides superior accuracy, index time and flexibility to meet the demands of modern fabrication. Our positioners are designed and engineered for a demanding environment—they are also mechanically robust to suit any size application.

 

Premier Welding Positioner Models Available

  • TT100 Welding Poisoner
  • TT210 Welding Positioner
  • TT500 Welding Positioner
  • TT530 Automated Welding Positioner (NEW)
  • TT535 Automated Tilting Welding Positioner (NEW)
  • RT2000 Welding Positioner

 

Many of our positioners have add-on options to customize the best positioner for your needs.

Browse the Line of Welding Positioners

TT100 Weld Positioner
TT100 WELDING POSITIONER
TT 500 Weld Positioner
TT500 WELDING POSITIONER

Welding Positioners WI 

Whether you’re looking to increase your bottom line, enhance the quality of your welds, increase production or give your employees a morale boost, our line of welding positions will deliver! Bancroft Engineering is a leading supplier of automated welding equipment located in WI, USA.  Give us a call today at 262-786-1880 or email: sales@bancrofteng.com

Read More
Automated Welding Machine Builder

How Much Are Welders Paid?

Insight from an Automated Welding Machine Builder 

 

The welder shortage has been a known issue for years. With many welders nearing retirement age, the younger generation can’t seem to replace them fast enough. The demand for welders isn’t slowing down either—The American Welding Society shows that there is an even larger shortage in our future. It’s predicted that there will be a deficiency of over 400,000 skilled welders by 2024.

  • The average age of a welder is 55
  • Less than 20% of welders are under the age of 35

As an automated welding machine builder out of Waukesha, WI, (Wisconsin is one of the top 5 states with the most welding jobs) we recognize the challenges to filling this skills gap. Read on to learn more about welding careers and pay.

 

How Much are Welders Paid — The Break Down 

With all of this talk of a worker shortage, what does that mean for salaries? In 2019, the US Bureau of Labor Statistics reported welders to make an average of $44,800/year. This being said, salaries can range greatly depending on location, skill and application.  Welding is a skill that can provide a good, stable living. But, just like any career, you won’t be earning top dollar right away—most have to start at the bottom and work their way up.

fabricator automated welding machine builder

Experience & Skill Matter

Years of experience and leadership skills are an essential piece of the welding salary puzzle. Other than the art of welding metal parts, here are just a few essential areas welders must be equipped with:

  • Understanding of blueprints and technical specifications
  • Ability to calculate dimensions
  • Insight for inspecting weldments and materials
  • How to maintain equipment and machinery
  • Critical thinking for processes improvements
automated welding systems

The Role of Welding Automation

Automation has become commonplace for many manufacturing companies. Welding can be a semi-automated process where only a few elements are mechanized, or it can also be completely automated with the use of robots. Automation does not eliminate the need for skilled welders, it simply frees up these professionals to perform more challenging tasks. Even with the use of automated welding systems, it’s essential to have the knowledgeable staff who understand the ins and outs of the process, how to overcome challenges and ensure a high level of welding quality output. In summary, welding automation means MORE opportunities for welders!

 

The Future of Welding – Automated Welding Machine Builder

At Bancroft Engineering, we are advocates of skilled welders and understand what an asset they are for our economy. The future of welding is bound to be an exciting one for those interested in learning new, emerging technologies! We offer cutting-edge welding equipment for manufacturers who need to get the job done right.  Give us a call today at 262-786-1880 or email: sales@bancrofteng.com

Read More
Automated Welding Systems

Conquering the Challenges of Welding Stainless Steel

Automated Welding Systems + Stainless Steel

Stainless steel has been gaining popularity in applications across the fabrication industry for many years. This is mostly due to the material’s corrosion resistance, strength and overall resilience. From kitchen appliances, automotive products, medical equipment and much more, stainless steel is found all around us. While this low-maintenance metal has many benefits, it can cause a variety of welding challenges and frustrations!

 

Welding Stainless Steel Quick Facts:

  • There are hundreds of grades of stainless steel.

  • The most commonly used stainless steel includes 304 and 316.

  • Stainless steel is best known for its corrosion resistance, strength and workability.

  • Stainless steel has low susceptibility for bacterial growth, making it a popular choice for food-grade and medical products.

  • Some stainless steels can be 3-5 times more expensive than mild steel.

 

Choosing the right manual or automated welding system and process is key. Read on to learn about the common challenges to welding stainless steel and tips to overcome them.

  

Chromium Oxide

The thin layer of chromium oxide provides stainless steel with its “stainless” characteristic. This layer is one of the main attractors as it protects the material from harsh environments. The challenge when welding stainless steel is avoiding damage to this layer with spatter or slag as this can cause vulnerability to the end product. Post weld cleaning with the proper tools is essential to avoid this challenge.

 

Temperature Input

The alloy content of stainless steel conducts heat at a much slower rate than carbon steel. This means, the heat from the arc won’t distribute as easily throughout the material—causing heat concentration in the weld pool. This will lead to warping, burn-through and oxidation. An indicator that too much heat is being used on stainless steel is when the weld begins to form a rainbow of colors. While the colors may look like a work of art, it’s a red flag that the end product may not pass welding quality tests.

 

GMAW vs. GTAW

Historically, gas tungsten arc welding (GTAW) was the preferable method for working with stainless steels. However, as technology has progressed, gas metal arc welding (GMAW) has become more of a standard. This is due to the use of semi-automated welding equipment combined with state of the art controls which provide fast deposition rates, regulates heat input and improves consistency. Get in touch with Bancroft Engineering to discuss the many benefits of welding automation for stainless steel.

 

Finishing Processes

Stainless steel requires special finishing processes once the weld is complete. Don’t make the mistake of using steel brushes or polishing pads that have been used before on carbon steel—this will damage the protective oxide layer. Whether you need a matte, brushed or mirror finish, it’s important to use stainless-specific finishing tools such as finishing discs, belts and other tools.

 

Automated Welding Systems + Stainless Steel

Mastering how to weld stainless steel is a vital part of fabrication. Bancroft Engineering has years of experience building automated welding systems for stainless steel applications. We can help you optimize your production equipment and make huge welding improvements! Ready to upgrade? Give us a call today at 262-786-1880 or email: sales@bancrofteng.com

Read More
custom automated welding machines

Custom Automated Welding Machines — Every Option

One-size doesn’t always fit all. The welding team at Bancroft Engineering knows first-hand the benefits of a fully customized, made-to-order solution! Whether it be a semi-automated or robotic welding system you’re on the hunt for, Bancroft’s custom automated welding machines use the latest technology to get the job done right.

Knowing that standardized equipment can’t always deliver the same result as a customized solution, we’ve created add-on options and custom configurations to all of our equipment to meet the demands of today’s manufacturing environment. Read on to learn more about all of our customization options.

  

Semi-Automatic & Fully Automated Options

Depending on your welding requirements, either a semi-automatic welding system or fully robotic option will be preferable.

With Semi-automatic welding, the operator is more in control. The operator will load the part and evaluate the process while in production. The semi-automated system will guide the part through the welding process, aligns the part to meet the specifications and repeats the process.

With fully automated welding machines, it’s a more hands-off experience. Either the welder or an automated piece of equipment loads the part and the robot takes care of the rest.

 

Why Automate Your Welding Process?

  • Offers reliable consistency and efficiency

  • Improves productions speeds

  • Increases weld quality (fewer part rejections)

  • Manageable to use by all operator experience levels

  

Custom Weld Lathes

Weld lathe machines are one of the most versatile ways to weld production parts. The Bancroft weld lathe family can be customized for vertical, horizontal or inclined drive orientations. Synchronized spindles and automated fixtures can also be added on for more optimized efficiency. Check out all of the available configurations available for our 605 circumferential MIG welder and the 1210 weld lathe model right here.

 

Custom Rotary Welders (Welda-rounds)

Bancroft Welda-rounds, commonly referred to as circle welders or rotary welders, are durable and compact tools to weld a wide range of parts. Our Welda-rounds can be built to offer both single or multiple torches, special frame configurations, powered index positioner bases, custom tooling options and much more! View our full line of rotary Welda-Round circle welders, right here!

 

Custom Seam Welders

Linear seam welders provide continuous welding from end-to-end. Seam welders are best used for single pass, full penetration welds of parts such as cylinders, cones, boxes and flat metal sheets. All of Bancroft’s seam welders can be fully customized to meet your needs with MIG, TIG-cold wire feeds and AVC.  Read more about our robust automated seam welders here.

 

Maximize Your Process with Custom Automated Welding Machines  

If you’re looking to optimize your welding process with improved efficiency and a stronger end-product, Bancroft Engineering can help! Our team of welding engineers have the experience designing completely customized automated welding systems for both small and large operations. Ready to upgrade? Give us a call today at 262-786-1880 or email: sales@bancrofteng.com

Read More
enhance weld quality

4 Tips to Enhance Weld Quality

Excellent weld quality helps to build a competitive advantage for your manufacturing business. With the right process in place, you will be able to regularly deliver durable, strong and clean welds to your customers. Read on to get our 4 simple tips to enhance weld quality.

  1. Proper Placement

  2. In-process Monitoring

  3. Use Automated Welding Machines

  4. Quality Assurance Checks

 

The Cost of Poor Weld Quality

Before we get into our tips, let’s review some of the most common welding problems:

  • Spatter
  • Porosity
  • Undercut
  • Deformation
  • Cracks
  • Poor weld penetration
  • Incorrect wire delivery

These issues are often structural in nature while also affecting the overall appearance of your part. Low weld quality will hurt your bottom line, be a strain on your work environment and negatively impact customer satisfaction. Some issues could even be a safety hazard resulting in damage, injuries to workers or worse!

 

Tip #1: Proper Preparation

The steps before the welding process takes place are some of the most critical! Learn more about tips to prepare metal before automatic welding right here. When you skip out on cleaning your metal surfaces, removing oxide layers or prepping the metals edge—you’re setting yourself up for disaster. It’s worth your time to complete all best-practice welding preparations so you can not only pass quality inspections but also get beautiful and clean welds!

 

Tip #2: In-Process Monitoring

Real time, in-process weld monitoring is a great way to stay on-top of weld quality and catch errors before they occur. Some techniques used today for process monitoring include sensors, lasers and vision-based monitoring. Seam tracking allows you to track weld position during the welding process. This results in better welds, improved path speed, decreased scrap and reduced cycle times. Check out our run-down of seam tracking and how to select the right solution for your project right here.

  

Tip #3: Automated Welding Machines

Using the proper welding equipment is the first step for ensuring high-quality welding output. Automating your process can keep welding pitfalls at bay. Up-to-date technology makes a huge difference when it comes to avoiding welding defects—automation makes welding more consistent and reliable.

Bancroft Engineering provides both standardized and customized welding solutions. From semi-automated welders to 100% robotic cells, our engineers can help you select the right system for your process. Check out more information about our welding system offerings right here!

  

Tip #4: Quality Assurance Checks

Our last tip for improving weld quality is to have strong quality control in place. A welding quality assurance inspector reviews the weld and tests it’s quality. Quality assurance checks should focus on the overall quality of the weld as well as the strength of the weld. The main benefits of having quality control in place is to catch problems, analyze them and determine the best way to fix the issue moving forward.

 

Step up Your Weld Quality

Bancroft Engineering is here to help you improve weld quality with state-of-the-art equipment. We offer both design and build services under one roof. Specializing in standalone semi-automated welding machinery and large, automated weld systems, we offer full-service welding support. Give us a call today at 262-786-1880, or email: sales@bancrofteng.com.

Read More
automated welding equipment builder

Steps to Prepare a Fab Shop for Automated Welding

Getting started with welding automation can be a big task, especially for first-time purchasers. In order to gain the desired results and a justifiable return on investment, it’s important to get started with the right implementation process.

Semi-automated welding machines or fully automated robotic cells can offer huge advantages for fab shops such as improvements in productivity, cost savings, time savings, higher quality parts and so much more.

Trends in Fabrication

Manufacturing trends and equipment technology are constantly evolving. With 2020 now underway, it’s important for your metal fab shop leaders to stay informed and proactive! Industries such as construction, automotive, food/beverage, aerospace and military/defense are all steadily growing markets and they all depend on metal fabrication. Here are just a few metal fab trends we are noticing:

  • Use of automation & semi-automation
  • New research and development technology
  • Reliable and intuitive production monitoring
Weld Lathe automated weldingMachine
Weld Lathe Machine

Take the time to prepare your fab shop for automated welding success with these simple steps.

 

Get the Team on Board 

One of the main tips we have for preparing your fabrication shop for automation is to adapt your team to the new technology. It’s crucial to consider your existing shop workers and how their jobs may be affected by the shift to robotic automation or the use of semi-automated welding equipment. We recommend you encourage opportunities for advancement, explain potential benefits and be transparent about the company’s goals. This will ensure your team is well informed and ready for the transition.

 

Identify & Conduct Training

Learning the skills of automation is a huge opportunity for welding professionals. Automation uses cutting-edge technology, which allows welders to gain an entirely new perspective of the manufacturing process—and the art of welding. Welding technology has improved so much over the past decade that it’s made learning automation and robotics easier than ever. With user-friendly interfaces and digital controls, automated welding equipment is designed for ease of use. Here are a few process and training elements to consider:

  • Determine which project to start automating
  • Select a team of welding system operators
  • Utilize training programs for equipment specific applications, software, maintenance, etc..
  • Address workflow shifts & action steps
  • Develop a clear quality control strategy

 

Selecting the Right Welding Automation Partner

A professional welding automation equipment builder will have experience with different welding applications and system configurations. The team at Bancroft Engineering has highly experienced engineers and support personnel that are here to help you from first concept, design and build of the automated machine and support through the equipment’s lifecycle.

  

Welding Automation Equipment Builder

Bancroft Engineering designs and builds welding equipment from standalone semi-automated machinery to large, fully automated weld systems. Located in Waukesha, WI, our team of welding engineers offer full-service welding support to help you automate and optimize your process. We’d love to help you get stared—give us a call today at 262-786-1880, or email: sales@bancrofteng.com.

Read More