welding positioners 101

Welding Positioners 101 NEW Automated options

How often do you notice your welders working hunched over or welding above their heads? The welding position affects EVERYTHING about the end result. Without a reliable configuration, quality, productivity and safety all suffer. Cue the welding positioner.

We’ve put together this basic guide on welding positioners and run through the many options we have to not only improve your welding operation but make it a whole lot easier.

 

Weld Positioner Applications

Positioners can be applied to a diverse mixture of applications, but they are most commonly used for the rotation of parts during the welding or assembly process. They provide a consistent plane of rotation even bearing a significant amount of weight.

Weld positioners can be used for both manual welding, semi-automated welding or used to complement a robotic system. A few of the key industries currently utilizing weld positioners include:

  • Heavy construction or machine manufacturing
  • Military
  • Automotive
  • Aerospace
  • Steel & pipe industries

Standard vs Automated

The welding positioners designed by Bancroft Engineering can be custom configured to fit your needs. These innovative options allow the positioners to be even more flexible and satisfy the most stringent of customer demands. All of our standardized positioners can be fully customized with one or many of the following options:

  • Increased torque capacities
  • Digital displays
  • Hardware and special hole patterns for easy fixture mounting
  • On/off foot switches
  • Safety locking
  • Aluminum tables
  • Other customizations upon request
automated welding positioner

If it’s more control you are looking for in a welding positioner then our line of automated positioners could be your solution.  Designed with both the harsh welding environment and cost in mind, these automated positioners can be integrated into any power supply.  They are PLC controlled and available with:

  • Programmable rotation distance
  • Variable speed and direction
  • Rotary delay and craterfill timers
  • A repeatable tooling home location
  • Manual or pneumatic torch shuttle
  • Live center
  • Tilt and pivot options for better weld positioning

Watch our TT530 Automated Positioner in Action!

Welding in the Right Position

One of the main perks of welding positioners is that you’ll always be in the best position and angle to generate high-quality output. Positioners also save floor space, give the ability to manage higher load capacities in a safe way and decrease cycle times. Along with production benefits, positioners produce a quick return on investment!

Read more on what to know about welding positioners in this blog post.

 

Choosing the Best Welding Positioner – Our line of Premium Positioners

TT100 Rotary Positioner: Ideal for small weldments weighing up to 100 pounds. Capable of handling up to 300 amps of welding current.

welding positoners

TT210 Rotary Positioner: 200 lb. vertical load rating. Capable of handling up to 300 amps of welding current.

TT 210 positioner

TT500 Rotary Positioner: 500 lb. vertical load rating. Capable of handling up to 500 amps of welding current.

Welding Positioner

RT2000 Rotary Positioner: 2,000 lb. vertical load rating. Capable of handling up to 1,000 amps of welding current.

welding positioner

TT530 Automated Positioner:  500 lb. vertical load rating, 500 amps of welding current, programmable rotation distance and repeatable torch locating mechanism.

automated welding positoner

TT535 Automated Pivoting Positioner:  All the specs of a TT530 with the ability to pivot up to 90 degrees into a fully horizontal position.

automated welding positioner

Get the full list of specifications for our weld positioners right here.

  

Looking for a positioner from a trusted and authentic supplier? Bancroft Engineering is a leading provider of semi-automated welding equipment. We design and build weld positioners in a variety of different specifications and can help you meet any custom requirement.

Get a Quote
Read More
automated welding trends for 2021

5 Trends in Automated Welding for 2021

Automation in the welding industry has been a growing trend since the 70’s. There has been an increase in demand from end-user industries and market growth continues to be on the upswing. These demands have been supported by the continued advancements in technology and R&D surrounding both automation and welding.

As we move into the New Year, we thought it would be worthwhile to review 5 trends in automatic and semi-automatic welding from our perspective.

Trend #1: Welding Safety Enhancements

Safety should always be number 1!  While this is not a new trend, fabricators will continue to take steps to keep workers safe. Without the proper safety precautions, automated welding can be dangerous. Here are just a few of the most common hazards:

  • Exposure to Gases & Fumes
  • Physical Hazards such as burns, eye damage, cuts, etc..
  • Electric Shock
  • Fire & Explosions

To improve the safety surrounding automated welding, we’ve seen more and more adoption of interlocking perimeter guards, safety light curtains, laser scanners, sensors, pressure-sensitive safety mats, high-quality gear, auto doors, better smoke extraction systems and more!

Auto doors with safety enclosure

Trend #2: Labor Shortage Issues

There’s been a lot of discussion around the welder shortage in the United States—it’s estimated that there will be a deficiency of over 400,000 skilled welders by 2024. This is an extremely challenging hurdle for manufacturers looking to expand and fill demands. At Bancroft Engineering, we understand what an asset welders are to our economy and the importance of education for the younger generation.

Trend #3: Automation Technology Growth

New technology will continue to emerge as we move into 2021.  New tools and technologies that will see growth include:

  • Power Sources
  • Digital Control Systems
  • Welding Management Software
  • Seam Tracking Systems
  • Gas Control Devices
Seam Tracking System
Automated Welding Positioner Prototypes
Automated Welding Positioner Prototypes

The team at Bancroft Engineering has been hard at work implementing new technology for all of our customized and standard semi-automated welding equipment. Stay tuned for the release of a new automated welding positioner and seam tracking systems coming later this year!

Trend #4: Rise of Collaborative Welding Systems

The welding industry will continue to embrace collaborative systems to compensate for the increasing skilled labor shortage in 2021. Collaborative welding systems are designed to share a workspace with humans—creating a safe and seamless automation environment.  This is one of the latest big trends in automated welding as it can be deployed easily, used for a variety of welding applications and are affordable compared to large robotic systems.

 

Trend #5: Adaptive Control Advancements

For those looking to improve their automated welding operation in 2021, adaptative controls are high on the list.  Adaptative control are used to analyze welding data in order to make corrections and improvements based on the results. These corrections are made automatically to the weld current—in real-time. This data is critical for improved quality and process optimization.

 

The Future of Automated Welding

With the use of new and improved welding technology, there are many opportunities to increase productivity and uncover time and cost savings. Technology advancements can help you address critical welding challenges which will allow you to stay competitive!  If you’re looking to adopt automated welding or make an upgrade, our team of trusted engineers are here to help you select the best equipment that will have the most impact on your business and bottom line.

Read More
welding positioners WI

What to Know About Welding Positioners

Photo above: NEW TT530 Automated Positioner

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

What are Welding Positioners?

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

Positioners Increase Welding Throughput

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

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

Positioners Improve Weld Quality

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

semi automatic welding positioner

Retrain & Attract Skilled Welders 

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

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

Premier Welding Positioners Available

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

 

Premier Welding Positioner Models Available

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

 

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

Browse the Line of Welding Positioners

TT100 Weld Positioner
TT100 WELDING POSITIONER
Rotary Welding Positioner
TT500 WELDING POSITIONER

Welding Positioners WI 

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

Read More