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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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

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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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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Precision Weld Lathe Machine Uses

Automated weld lathe machines are designed and built for both small and large welding applications. Lathe welders are commonly used to weld seams or to join multiple components together. Here at Bancroft Engineering, we take pride in building the best precision weld lathes for manufacturers looking to automate—or just improve their overall welding processes!

 

About Weld Lathe Equipment

Precision weld lathe machines provide a versatile way to rotary weld production parts. Whether you’re in need of vertical, horizontal or inclined drive orientations, a weld lathe can be aligned to optimize and improve your production line. Check out Bancroft’s line of premium weld lathe machines below:

Model 605: The fully functional 605 model welder is a budget friendly alternative for circumferential welding cells. This system is designed to achieve a maximum welding rates as well as high-quality output with minimal labor costs.

  • Precision machine bed
  • Digital controls
  • 500 lb load capacity
  • Auto cycle operation
  • 400 lb camping force at 80 PSIG

VIEW ALL 605 SPECIFICATIONS

precision weld lathe machine

Model 1210: This welding lathe is powerful yet designed with simple setups in mind. It offers more consistency and repeatability than less controlled welding methods.

  • Precision machine bed
  • Digital controls
  • 1000 lb capacity
  • Auto cycle operation
  • 650 lb clamping force at 80 PSIG

VIEW ALL 1210 SPECIFICATIONS

precision weld lathe machine

Synchronized Drive Lathe: These automated lathe machines are used to join two or more components that have radial orientation. With the focus on speed and quality, Bancroft’s synchronized drive weld lathes are versatile and production ready. Check out more details here.

 

Top Industries

Whether you have large parts or small, precision components, our wide range of lathe configurations can be used to meet your needs. Bancroft Engineering builds standard and customized weld lathe machines for a wide-range of industries and applications including:

  • Automotive components (exhaust, wheels, suspension, torque converters, etc.)
  • Hydraulic cylinders
  • Pressure vessels
  • Tanks
  • Construction applications
  • Military components
  • Job shops & metal fabricators

 

Customizable & Flexible

Looking for something specific? Weld lathes can be customized to fit any circumferential and linear TIG, MIG or plasma welding requirement. Leave it to our team of highly skilled engineers and technicians to build a custom weld lathe machine that exceeds your expectations.

 

Precision Weld Lathe Manufacturer

We strive to design and build the right equipment for your job! From standalone solutions to complex fully-automated systems, our work is always backed up with quality installation, field service and support.

Bancroft Engineering designs and builds welding equipment out of Waukesha, WI—specializing in stand-alone machines to fully robotic automated systems. Ready to learn more about adding a precision weld lathe machine to your shop floor? Call us at 262-786-1880, or email: sales@bancrofteng.com to get started.

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weld lathe machine

NEW Weld Lathe Machine + Secondary Operation Add-On

We are proud to be offering NEW weld lathe equipment that also includes added-value operations—all in one piece of machinery. Our standard 605 and 1210 model circumferential welding systems have always been designed with flexibly in mind. Now, we are offering the availability of even more options to customize a solution to fit all of your welding, machining and other fabrication needs.

We believe that your next piece of automated welding equipment should perform above average! These brand-new lathe machines with added machining applications offer high repeatability, extreme consistency and minimal run-out.

Value-Added Operations

Along with our standard welding machine product lines, Bancroft Engineering also provides customized solutions to fit the demands of any project. We now offer the possibility of adding secondary operations.  Have metal parts that need to be welded and drilled? Now, this can be done all in one machine—saving time and labor while optimizing your production line.

Machining Secondary Operation Add-Ons:

  • Drilling
  • Milling
  • Cutting
  • Custom machining tasks
weld lathe machine

Standard Machine Features

Bancroft’s weld lathe family is one of the most versatile ways to rotary weld production parts. Our standard product line of weld lathe machines come with a plethora of features and specifications:

  • Accurate machine bed
  • Modern digital control System
  • DC rotary drive
  • 500-1000 lb. load capacity
  • Automated cycle operations
  • Adjustable operator console
  • 400-650 lb. clamping force
  • 4”x4” cross-side torch adjustability
  • Standard air-cooled torch
  • Much more…
  • See All Standard Features

Weld Lathe Custom Configurations

  • Multiple weld torch & frame configurations
  • Programmable torch positioning
  • Torch Weaving
  • Programmable multi-pass welding
  • Machine enclosure and flash shields
  • TIG, plasma or submerged arc applications
  • Tooling and factory runoff
  • Much more…
  • See all Custom Options

Weld Lathe Machines + Secondary Operations Combined

We are excited to expand the weld lathe family to include value-added machining operations.  Bancroft Engineering designs and builds welding equipment out of Waukesha, WI—specializing in stand-alone machines to fully robotic automated systems.

Ready to take the next step? Call us at 262-786-1880, or email: sales@bancrofteng.com to get started.

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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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