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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!

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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—Best Weld Positioner

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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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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