custom welding solutions process

Custom Welding Solutions Designed for You

Bancroft Engineering puts the “custom” in customer service nearly every day.  We often receive inquiries from companies that are looking for help in developing a custom solution for a particular welding application—ranging from optimizing a specific process to tooling to a turn-key welding system.

 

These inquiries not only come in from existing customers who are looking to perform additional tasks with their Bancroft systems but also new customers who want to improve their manufacturing efficiency for the very first time.

 

We take pride in helping companies develop customized automated welding solutions when our standard products aren’t a viable fit for their specific application.

 

Our welding process development stages are designed to streamline your manufacturing operation. We take the time to understand your goals and pain points before putting together a solution that meets your needs. Read on for the breakdown of our complete custom welding solution process.

custom welding system

Pictured: A custom welding system built by Bancroft, both outside and inside of tube.

Step 1: Inquiry/Needs Analysis

The inquiry/needs analysis phase begins with the initial request regarding a need for a custom solution. Bancroft’s technical staff will work closely with your team to understand your automated welding problems and expectations.  This step often includes photos of your current machinery, part prints, videos and phone discussions. Get started improving your welding process by filling out our contact form here.

 

Step 2: Develop Solution

Our technical sales and engineering teams combine forces to brainstorm all the possible welding solutions during the solution development stage. At times, this is a collaboration between both companies or can be done entirely by Bancroft. We leave this decision up to each individual customer.

 

Step 3: Proposal, Budget & Timing

The proposal can come in the form of a single best solution to the problem or possibly numerous solutions depending on customer requirements. We will walk you through each solution, the timeline required and what results can be expected.

 

Step 4: Construction

The construction phase has many steps. Mechanical design, electrical design, fabrication, mechanical assembly, electrical assembly and testing are the basic construction steps. Often, this is a collaboration between Bancroft, our suppliers, the customer and their suppliers in order to build the optimal system.

 

Step 5: Support

After the construction process is completed, the time comes to put your system into production. If needed, Bancroft can assist you to integrate the new automated welding system on your shop floor. Regardless of your needs for assistance, one of our engineers will follow up with you to ensure the solution is properly addressing the initial problem and is working as expected.

 

Custom Welding Solutions by Bancroft

If you have any questions about our process or would like to inquire about a customized welding system for your company, please don’t hesitate to call us at 262-786-1880.  Or email us at sales@bancrofteng.com to get started.

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welding machine

Trade-In Trade-Up Welding Machine Program

Is your Bancroft Welda-round starting to show signs of aging?  Do you think it might be time to replace your old Bancroft welding machine and trade-up to a newer, more efficient model that can truly fit your needs?

 

We recently had a customer approach us with this exact situation.  We started our normal process of quoting them a new machine and/or to rebuild their existing equipment.  They responded with, “I like the rebuild idea, but we cannot afford the downtime.”

 

welding machines

Bancroft Rotary Welding Machines

 

This got our sales team thinking! “We either need to stock a refurbished 300 Welda-round so we can send it to our customer and trade them for their current machine.  OR, can we send a new machine at a discount and take their old machine in on trade?”

 

The answer?  Our new Trade-In Trade-Up Program!  Trade-in your old Welda-round and your new rotary welding machine will come with all the same options as your current machine plus give you the capability to add on more features to suit your needs.

 

We hope our new Trade-In Trade-Up offering will significantly help our existing customers. Here are a few big perks for utilizing this new program:

  • Use the latest and greatest in automated welding technology
  • Ensures you’ll get a great price for your former or out-dated machine
  • Eliminates the inconvenience of downtime
  • Removes the hassle of waiting for the older machine to be sold, uninstalled and moved out of the way

 

Get Started with the Trade-In Trade-Up Welding Machine Program

 

To trade-in your old welding machine, simply send us a picture of it. Within 48 hours you will receive a quote that will include your trade savings.  We guarantee a minimum of $5,000 in savings regardless of your machine’s condition!

 

Included in this program, Bancroft will offer FREE shipping of your old equipment back to our plant in Waukesha, WI.

 

For complete details, call: 262-786-1880 or email us at sales@bancrofteng.com.

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Automated welding equipment

Automated Welding Equipment: To Replace or Not to Replace?

It can be difficult to know if you’re making the right decisions when it comes to automated welding equipment expenses. How do you know if it’s the right choice to purchase a new piece of equipment or continue to repair an old one? We’re here to help ease that decision process. Read on to learn if you should or should not replace your current automated systems.

 

First, can you afford downtime?

If you’re running five welders and one goes down, that’s a much different situation than if you’re running one or two and lose one—that’s at least half of your production lost!  Some businesses can’t afford downtime, while others prefer to maintain older equipment.

 

Next, assess what life is still left in your current automated welding equipment

It’s important to understand what the annual maintenance costs are of all your current welding systems. Tracking those costs over time is one of the best indicators of the longevity of a machine. It’s safe to say that almost all machinery will inevitably wear out. Knowing what you’ve invested into the machine over the past few years will give you a baseline of where it’s at when you’re looking at making the decision to either replace it with a new system or retrofit the welding equipment completely.

 

automated welding systems

 

For example, if a machine is 15-20 years old and in the past decade all you’ve done is routine maintenance, it’s more likely you’ll soon face a major repair. So, it might be a good time to look into buying a new piece of equipment. However, if you have an older machine you recently overhauled or refurbished, it’s probably better to hold onto it and reap the benefits of your investment.

 

Automated welding equipment

Finally, are the critical electronic components still available?

In today’s innovative manufacturing world, electronic manufacturers are making components obsolete and discontinuing production of system components earlier and earlier. Make a list—or ask the manufacturer for a list—of the critical components. A quick internet search will take care the rest.

 

Still not sure?

If you decide it’s time to replace your welding equipment or retrofit an older machine, give Bancroft Engineering a call and let us make the next 20 years worry free!

 

Bancroft Engineering, located in Waukesha WI has years of experience designing, building and updating automated welding equipment for every sized project.

 

Request a Quote Today

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Google vs. Bancroft + Happy Holidays!

welding automation

GOOGLE, What do people most frequently ask about welding?

 

  1. What does it take to be a welder?
  2. Are welders in demand?
  3. Why do welding rods stick?
  4. How long does it take to become a welder?
  5. Do welders make good money?
  6. What is the highest paid welding jobs?

 

GOOGLE, What are the most difficult questions to answer about welding?

welding automation

 

  1. Is it better to use fixed welding automation or a robot?
  2. Can an air-cooled robotic MIG gun be used instead of a water-cooled gun?
  3. What is the benefit of touch sensing?
  4. Do I need a seam tracking system?
  5. What type of payback can be expected from an automated welding system?

 

GOOGLE, Is there an expert that can help me make decisions about welding automation?

 

 

Bancroft Engineering New Logo

 

 

While Google might have the answers to the simple questions, let Bancroft answer the more complicated welding automation questions! We take the time to understand your welding requirements and offer advice that is customized to your needs. Bancroft Engineering offers a wide range of standard welding equipment such as weld lathes, synchronized drive lathes, linear welding systems, seamers and more. We also offer custom equipment and robotic welding cells to fit any part size, weight or geometry.

 

Get in touch with us today to get ALL of your automation questions answered

 

As 2018 comes to a close, we want to say thank you to all of our customers, vendors and business partners.
Our team wishes you a great holiday season!

 

 

Bancroft Engineering
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Longitudinal Seam Welder

Should You Upgrade to a Longitudinal Seam Welder?

If you are currently using a manual process to do your linear welding then this article is for you. We have highlighted the benefits of upgrading to a Bancroft longitudinal seam welder and show you how it can improve your welding process. No matter what type of parts you are seam welding, automation can help you to increase your productivity while decreasing welding errors.

 

For many industrial applications, it is necessary to form the material into cylinders or rectangular tubes within the part production process. The edges are then welded together to form a rigid structure. Instead of holding the edges in alignment and manually tack welding, longitudinal seamers provide the aide of automation.

 

Automated longitudinal seam welders offer many benefits and also help to eliminate common problems such as:

  • Leaks around tack weld areas
  • Uniformly chilling of the joint to prevent distortion and oxidation
  • Dimensional accuracy and repeatability problems

 

Welded linear seams are uniform across the entire length and can be done using a variety of welding methods:

  • MIG
  • TIG
  • Submerged Arc
  • Plasma
  • Laser

 

Longitudinal Seam Welder

 

A longitudinal seam welder gives the operator repeatability with the touch of a button.  Seamers increase production while providing consistent quality welds from piece to piece.  These machines are cantilevered from one end to allow loading and unloading of open and closed sections directly to the mandrel arm.

 

Longitudinal Seam Welder

 

Seam welders can be used for external or internal welding applications.  Below is a photo example of an internal process:

 

Longitudinal Seam Welder

 

There are many ways to weld a seam.  Browse our website for more information and give one of our engineering experts a call.  We can walk you through the options and help you decide what equipment will improve your welding process the most.

 

Request  A Quote

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automated welding system

Looking to Automate Your Welding Process?

Pondering between fully or semi-automatic welding systems?

 

Fully automated robotic welding strives to completely remove the need for skilled labor to produce welds. Everything is done by the machine itself from setup to production—all the way down to the cleaning of the welding torch. While the initial equipment investment tends to be higher, there are many advantages to fully automatic welding over manual welding:

  • Produces more consistent welds
  • Ideal for large volume production
  • Higher quality welds
  • Improves worker safety
  • Reduces production cost

 

automatic welding systems

 

A popular alternative to fully automatic welding is semi-automatic welding systems.  These machines generally require an operator to load and unload product. Depending on the job, semi-automatic systems can be as efficient and many times easier to operate than a robotic system.

 

automatic welding systems

 

Bancroft offers a wide variety of equipment for both fully-automatic and semi-automatic welding. Both types of equipment offer processes that are much quicker and more effective than manual welding. It also produces better, more consistent welds than welding by hand. There is an even greater benefit if larger welds are involved, multiple passes are needed, or higher part quantities are being produced. Automated equipment is also ideal for industries where weld strength plays an important factor, as the welds are of higher quality.

 

Bancroft is always ready to start a completely custom machine design and also has a variety of standard semi-automatic welding equipment in stock including welding positioners, Welda-rounds, and weld-lathes.

 

Request a Quote

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Rebuilding Your Aging Welding Equipment

Rebuilding Your Aging Welding Equipment

Using outdated or broken welding equipment can be hurting your company’s productivity, quality, ROI and more. The cutting-edge technology that was out 5-10 years ago is far behind the welding equipment of today. Rebuilding your current, outdated machines can improve welding performance and give you the reliability your company needs.

 

Bancroft does more than offer new welding equipment—we can rebuild and update your old and worn out machinery, whether you purchased it from us to begin with or not.

 

Benefits of Rebuilding Your Aging Welding Equipment:

 

  • Saves money
  • Extends equipment life
  • Decreases downtime
  • Increase welding quality
  • Optimizes power efficiency
  • Decrease training time
  • Expands machine’s versatility

 

During the rebuilding process, Bancroft will make aesthetic improvements, replace any worn parts, inspect the machine for future problems and update all welding components that may have become obsolete.

 

Featured below are the before pictures of our 300 Welda-Round that has been in use for many years. This machine has just been updated by Bancroft.

Rebuilding Your Aging Welding Equipment

 

The photos below are what it looks like after the upgrade was completed.

Rebuilding Your Aging Welding Equipment

 

 

How old is your welding equipment? Today’s state-of-the-art welding technology will make your equipment run more efficiently and create an immediate payback.

 

Give us a call and we can help you make your welding equipment look and function like it’s brand-new!

 

Request a Quote

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Section 179 Expensing

Take Advantage of Section 179 Expensing in 2018

If you’re in the market for automated welding equipment of any kind, there has never been a better time to invest in innovation from Bancroft Engineering. There is still time to order and have your machine delivered by the end of the year. Our schedule is filling up quickly, so act now!

 

We would like to remind our customers that Section 179 of the United States Internal Revenue Code (26 U.S.C. § 179) has been restored to a write-off of up to $1,000,000 for 2018.  To qualify, the equipment must be:

  • Installed and placed in service during the same tax year
  • More than 50% of the use of the equipment must be used for the business

 

In addition, a bonus depreciation is extended through 2018 for all businesses who have purchased over $2.5 million in equipment. This bonus depreciation is 100% in 2018!

 

How does all this work? Our accountants have provided us with the following examples to help explain it:

Section 179 deduction is not a complicated tax code, it is one of the few government incentives available to small business. When a company buys equipment, whether by a cash purchase or by financing it, the company typically spreads the expense over several years through depreciation.  For example, if a company buys a machine for $100,000, the company can expense about $20,000 per year through depreciation for 5 years. Section 179 allows that company to expense the entire $100,000 during the current tax year if there is sufficient income to offset the expense, thereby accelerating the tax savings.

 

Section 179 Expensing Example:

  • Cost of Equipment After All Bancroft Discounts: $150,000.00
  • Section 179 Deduction: $150,000.00
  • Total First Year Deduction: $150,000.00
  • 35% Savings on Equipment Purchase: $52,500.00
  • Lowered Cost of Equipment After Tax Savings: $97,500.00

 

Remember! Our calendar is almost full for 2018. Contact us today to get your welding machine shipped by the end of the year so you can take advantage of Section 179 expensing.  Visit www.section179.org for more details.

 

Get in Touch

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welding positoners

We are Dedicated to the Continuous Improvement of Our Products

You can count on Bancroft Engineering to deliver the most complete line of automated welding equipment. Welding positioners are no exception. Our line of welding positioners are designed to rotate your workpiece at your desired angle and speed. Choose from our newly upgraded product line of bench-top to heavy-duty positioners with options to meet your welding automation needs. Made in the USA, these machines are designed for workpiece weights from 2lbs to 2,000lbs in vertical positions.

 

We recently improved our TT100 and our TT500 welding positioners. Product upgrades like these, keep us ahead of the competition, provide higher quality products, and allow us to offer more options to meet your welding requirements.

 

TT100 Welding Positioner

Pictured above

The TT100 is a low cost, robust solution for most lightweight needs (less than 200lbs). It has been upgraded to include the ability to add a digital speed display, remote foot pedal, and upgraded motor speed control, among many other available options.

 

TT500 Welding Positioner

welding positioners

 

The TT500 has 3 large upgrades. It now comes with a 2” through hole for longer parts and fixtures along with the ability to add a digital speed display. It also has the option to add a stand and/or Allen Bradley PLC to move a torch slide, rotate set degrees, and start and stop the welder.

 

Check out our full line of welding positioners here

 

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automate your welding process

Is it Time to Automate your Welding Process?

Bancroft Engineering offers both semi-automated machines and fully-automated systems to help with all your welding needs. From our Welda-Rounds and Weld-Lathes to vision-guided robotic systems, we have the equipment to improve your process.  When you automate your welding process, it can improve quality, productivity, lower your labor costs, and increase the reliability and consistency of your operation.

 

How repeatable are the welds you are making?

If your weld process is repeatable, a semi-automated system would be perfect for you. It produces at least 2 times the output as a skilled welder, which can drastically reduce labor costs. Making the switch can eliminate mistakes and there are also tremendous savings in scrap material.

 

welding automation value

What is the value of the product before the weld?

If the value of the product is very high before the weld is made, considering either a semi or fully automated system could prevent costly mistakes. Both systems eliminate mistakes caused by human error. They produce the highest quality weld every single time and offer much faster speeds.

 

welding automation value

What is your budget?

Prices for both semi and fully automated systems have dropped significantly in recent years. Robotic systems now have a lower initial investment, increase productivity and can produce an ROI in less than a year. Set up times are minimal, and mistakes are non-existent.

 

Are you better than the competition?

welding automation

As technology advances, so do our competitors. Are they using automated systems? If you want to beat out your competition, you can easily become more productive and profitable by having the best equipment in the industry.

 

Next Step?

Contact the knowledgeable sales team at Bancroft Engineering to see how our products can benefit you!

 

Request a Quote

 

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