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

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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

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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

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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.

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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.

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welding seam tracking

Selecting the Right Seam Tracking Solution

In today’s highly competitive market, manufacturers must stay both lean and efficient. Taking advantage of the different seam tracking options available for your welding projects is one way to gain an edge.

Here at Bancroft Engineering, we understand the importance of optimizing your welding process.

Tactile Seam Tracking

Tactile seam tracking systems track the seam using a sensor with a tip that physically touches along the length of the seam about 2-3” in front of the arc. When a change in location or alignment is detected, the system responds and adjusts to the correct position. It can be used in almost any welding process.  Tactile seam tracking is very versatile and works well on any material type. This option offers a great balance between cost and flexibility.

One disadvantage to tactile seam tracking is that the torch is adjusting in real time according to where the probe is touching not where the torch is welding.  If the probe is 3” in front of the arc and a quick drastic change to the seam is detected the arc may actually move outside of the seam. To solve this problem the tracker can be paired with another type of control system to delay the correction in relation to the travel speed of the weld head or part.

tactile seam tracking
Tactile Seam Tracking

Through Arc Seam Tracking

Through arc seam tracking is a type of 2-axis real-time tracking.  The tracking occurs as the weld is being deposited and adjusts by monitoring the voltage across the arc.  In order to shift along 2 axes’ with through arc tracking weaving is required.  As the tip to work distance changes so does the voltage across the arc.  This change in voltage is monitored and used to adjust the path of the torch, maintaining proper weld position in the joint.

through arc seam tracking
Through Arc Seam Tracking

Laser Vision Seam Tracking

Laser based vision tracking, also referred to as optical tracking, involves a laser beam device which hits the welding surface, reflects off and bounces back to the sensor. With this technology, the sensor then recognizes exactly where the seam is located. Laser vision seam tracking is highly reliable and great for high speed welding applications for both small and large parts.

laser vision seam tracking
Laser Vision Seam Tracking

Touch Sensing

Touch sensing, or wire touch sensing, is the physical touching of the weld wire to the welding surface to detect the joint. Most commonly used in robotic welding applications, this type of seam tracking uses low voltage through the welding wire or torch tip to search and detect the welding surface and seam.  The seam needs to be detected prior to welding so the cycle time can be double or more compared to that of other methods.

touch sensing
Touch Sensing

Each tracking system has its positives and negatives.  Work with a Bancroft weld specialist to understand which one is the best option for your process.  Located in Waukesha, WI, our team of welding engineers are here to help you automate and optimize your process. Give us a call today at 262-786-1880, or email: sales@bancrofteng.com to get started.

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Semi-Automatic Welding Machine

Semi-Automatic Welding Machine –The Best Choice

 Ready to optimize your manual welding process to a more efficient operation and consistently improve your end products? Updating your welding methods with a semi-automatic welding machine will take your manufacturing process to the next level—all while increasing your profit margin.

Robotic or fully automated welding is not ideal for every project—expected lifetime of the job, the cost of tooling and the flexibility required are all factors that should be considered. That being said, semi-automated welding systems are a great option because they can double the output of a skilled manual welder while still maintaining a high level of control.

  

What is Semi-Automatic Welding?

Semi-automatic welding is a form of manual welding that utilizes the proper equipment which automatically controls one or more of the welding conditions. The machine operator manipulates the controls of the machine to start welding and observes the process and end result for quality. This is helpful to workers as it’s much less physical demanding than manual welding.

 

Advantages of Semi-Automated Welding Machines

Applications that benefit most from semi-automated equipment is when the quality or function of your weld is highly critical, if repetitive welds must be made, or if the parts already have gone through added-value processes before the welding begins. Semi-automatic welding systems offers a host of advantages for a variety of applications:

  • Enhances worker safety
  • Maintains high-quality welding output—integrity and repeatability
  • Increases overall product output
  • Decreased scrap produced
  • Less expensive than robotic welding

Ready to upgrade to an automatic welding system? Contact our welding engineers today.

Welding Machine Types for Every Application 

Bancroft Engineering specializes in robust semi-automatic welding machines—both standardized and custom solutions. No matter what type of welding projects you have, semi-automatic machines give you repeatability with the touch of a button!

semi automatic welding system

Weld Lathes:  Our line of weld lathes are built for speed and quality output. We also offer lathe machines that include built-in secondary operations such as drilling, milling and cutting to maximize your production line even further.

Rotary Welding Equipment: Economical, compact and robust, our line of Rotary Welda-Round machines are a great option for welding operations dealing with a variety of parts and material types.

Seam Welding Machines: Seam welding is common in many industries after forming materials into cylinders or tubes. Semi-automated seam welders are able to create uniform consistency across the entire length of the material.

Linear Welders:  Linear welding systems are designed to automate straight welding applications. These machines are commonly used for both small and large-scale projects.

 

Semi-Automatic Welding Systems Built in Waukesha, WI

Our team offers welding equipment from simple rotary and linear drive machines to multi-axis, servo systems with robotic integration. Interested in learning more about Bancroft Engineering and what we can do for your welding process? Get in touch with us to discuss your project!

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Rotary Welding Machine Display

See You at FabTech 2019

When:  November 11-14, 2019

Where:  McCormick Place
2301 S. Martin Luther King Drive
Chicago, IL 60616

FabTech is North America’s largest metal forming, fabricating, welding and finishing event! This November, plan to attend the FabTech show in Chicago for 4 days of the latest manufacturing technology. Meet with world-class suppliers and see all the latest industry equipment and developments. You’ll be sure to find tools to improve your productivity, increase profits and discover new solutions to all of your manufacturing needs.

Welda-Round Rotary Welding Machine on Display

During the show, we will be demonstrating our Model 300 rotary Welda-Round machine. This demonstration will be highlighting a torch system built by American Weldquip.

We will be showcasing some of the latest technology and controls to conquer the toughest weld jobs with ease. The durable and versatile Model 300 welding system is designed to produce fast, repeatable, flat circular or contoured welds. Don’t miss it in action!

rotary welding machine
rotary welding machine display at FabTech

Stop by booth B17059 during the FabTech show to see Bancroft Engineering and our partner, American Weldquip! We will be located in the North Hall, which is sure to be filled with a wide range of welding and other finishing technologies. Our team will be available to discuss your manufacturing projects and to answer all of your questions. Learn more about Bancroft Engineering’s services and equipment by watching our latest video below:

 

Join us at FabTech 2019

Interested in learning more about Bancroft Engineering and what we can do for your welding process? We will have sales engineers at the show to answer all of your questions and to discuss your specific projects.

If you’d like to schedule a time to meet with one of our team members before or after the show, email us at sales@bancrofteng.com or call: 262-786-1880. We’d love to hear from you!

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welding machines

Section 179 Expensing for Welding Machines in 2019

With the new year right around the corner, it’s a great time to plan for tax savings before it’s too late. Purchase automated welding machines from Bancroft Engineering to not only improve your manufacturing process but also to save your business money during tax time.

 

How Does Section 179 Expensing Work for Welding Equipment Purchases?

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 $1,000,000 of a qualifying equipment purchase for 2019.

In previous years, when businesses purchased welding equipment, they would write it off little by little through depreciation. For example, if your business spends $75,000 on a piece of machinery, you might write off $15,000 per year for five years.

Now, with Section 179, a business can write-off the entire purchase price of qualifying equipment for the current tax year. As in our previous example, if your manufacturing business spends $75,000 on a piece of automated welding machinery, you can write off all $75,000 in the same tax year using Section 179. This makes a big difference for small and medium-sized businesses as it allows you to accelerate your tax savings!

How to Qualify for Section 179

Section 179 is an attractive tax deduction for manufacturing businesses—it’s also easy to understand and utilize. 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 the business

 

Real Example of Section 179 Expensing

  • Cost of equipment after Bancroft Engineering Discounts: $175,000.00
  • Section 179 Deduction: $175,000.00
  • Total First Year Deduction: $175,000.00
  • 35% Saving on Equipment Purchase: $61,250.00
  • Lowered Cost of Equipment After Tax Savings: $113,750.00

 

Utilize Section 179 with Your Next Automated Welding Machine Purchase

There has never been a better time to purchase welding equipment and take advantage of major savings!

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.

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welding positioners

Best-in-Class Welding Positioners

Most of us know how important the proper positioning of a workpiece is to get high-quality welds. Positioning equipment assists the welder when both maneuvering and welding small and large parts. Positioners for welding greatly enhance productivity—they can be used as both stand-alone units or as a part of a complete automated system.

All of our best-in-class welding positioners provide years of reliable and productive service. Read on to learn more about Bancroft Engineering’s best-in-class welding positioners.

  

About Welding Positioners

Positioners are used to securely hold, rotate and lift weldments in order to assist the welder—or the robot—to access the joint at the optimal orientation. Positioners offer many benefits such as improving the quality of the weld, improving production speed while minimizing worker accidents.

 

Key Welding Positioner Machine Benefits:

  • Enhances worker safety
  • Increases throughput
  • Lowers labor costs
  • Improves weld quality

 

Engineered for Every Application

Bancroft Engineering offers the most complete line of weld positioners for every application and budget. All of our high-quality welding positioners are designed to rotate your workpiece to the exact angle and speed to meet your needs. Choose from light, medium or heavy-duty positioners with all the add-on options to exceed your welding automation requirements.

MODEL TT100

This light-duty welding positioner is designed for high speed rotation of lighter workpieces. It includes many of the same features of higher-capacity positioners such as variable speed control, forward/reverse switch control and much more. It has a compact design, plus it’s perfect for both MIG and TIG welding applications. The TT100 positioner is the #1 choice for smaller weldments with weights up to 100 pounds. SEE ALL TT100 SPECIFICATIONS HERE.

welding positoners

MODEL TT210

With a 200-pound vertical loading rate, this robust weld positioner is a great solution for any automation or manual welding application. The TT210 is easy to adjust and offers a 90-degree tilt. It features variable speed control, adjustable overlap control and much more. SEE ALL TT210 SPECIFICATIONS HERE.

TT 210 positioner

MODEL TT500 

Our model TT500 offers a powerful solution for consistently rotating and holding parts in your workstation. This robust positioner features a 500-pound vertical load rating and a 120-degree tilt. Along with the basic features, it also offers a 2-inch center through hole for increased security and purging. SEE ALL TT500 SPECIFICATIONS HERE.

Welding Positioner

MODEL RT2000 

Designed for the rotation of larger work pieces, the model RT2000 provides an option for all of your heavy weldments. This high-quality positioner works to smooth your operation with minimal backlash. With a 2,000-pound vertical load rating, this weld positioner features a slotted turn table that provides quick mounting of multiple fixtures. The RT2000 is also available with servo motors for a robotic application with custom controls. SEE ALL RT2000 SPECIFICATIONS HERE.

standard welding accessories

Need a More Automated Positioner?

We are getting ready to release a brand new welding positioner stand with even more controls and added features. Stay tuned for more information!

positioner for welding

Positioners for Welding Built in Waukesha, Wisconsin USA

Our positioners are available to all fabricators interested in high-quality and economical welding methods. Our engineering team ensures that each piece of welding equipment is built to satisfy the need for high quality and peak production efficiency.

Bancroft Engineering designs and builds welding equipment such standardized and custom welding positioners and much more out of Waukesha, WI—specializing in stand-alone machines 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.

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