Welding Machine Support

Welding Machine Support – We’re Here to Help

We know how stressful it can be when welding systems don’t perform like they’re supposed to. We also understand the negative impact it can have on your business when tech support can’t be there to help when you need it most. At Bancroft Engineering, not only do we craft high-quality robotic welding machines, but we also offer incredible welding machine support.

 

Help When You Need It

When you partner with Bancroft Engineering for your automatic welding system needs, we are dedicated to preserving this partnership for the long haul. That means that we offer services to help you protect your investment.

  • Complete Documentation Packages
  • Remote Diagnostic Access
  • Phone Analyst Support
  • On-site training, troubleshooting and repairs

Our response time during these situations is second to none.  Using the combination of our welding system maintenance staff and our large in-house spare parts inventory, we will have your equipment running as soon as possible.

Qualified Welding Technicians

Our experienced field engineers are qualified welding technicians who specialize in getting your machine back in action as quickly as possible. In fact, we’re so committed to the safety and effectiveness of your machines that we also offer preventative maintenance welding programs. This allows you to stop a problem before it even becomes one.

We only hire the very best to care for your machines; each of our welding technicians have programming, electrical and mechanical skills. They can perform (or supervise) on-site machine help with tasks such as repairs, upgrades and evaluations. Rest assured that our team of specialists will have you back up and running in no time at all.

welding machine technician

Extend the Life of Your Welding System

We also offer upgrades and rebuilds for welding systems that may have become outdated or worn. Bancroft can provide retrofit packages and upgrades to modernize and extend the life of just about any welding system. Our retrofits and upgrades offer you several benefits, including:

  • Cost-effective solutions
  • Increased productivity
  • Improved equipment reliability
  • Decreased future maintenance costs

With our help, you can be sure that your equipment will continue to offer high-performance welding solutions for many years. To learn more about retrofitting, upgrades and more, visit our page specially dedicated to welding machine support.

welding machine support.

Robotic Welding

Whether you are just beginning to consider entering the world of robotic welding or you are looking to upgrade your current equipment (or anywhere in between), we are here for you. Bancroft Engineering is committed to providing you with high-quality automatic welding machinery and excellent customer service. Give us a call today to learn more about how we can help you!

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welding power supplies

Types of Welding Process and Power Supplies

Photo Above: MIG Welding Process

The primary function of a welding power source is to convert electrical power into a current type that is suitable for the welding application being performed.  There’s a lot to consider when selecting the best power source for your welding systems.

Whether you’re looking to invest in new manual welding machines or ready to upgrade an outdated welder to a more modern piece of automatic welding equipment, we’re here to simplify the process. Read on to learn more about welding power sources and what key factors to consider before making a purchase.

 

Getting Started

There are a variety of power sources to choose from. To make the best choice, you need to pair your material type with the welding process and the best method of supplying power to the arc.

Choose your Welding Process 

Both the welding process and material type play a big role when selecting a power source because they are not always compatible with each other.

Gas Metal Arc Welding (GMAW) or Flux-Core Arc Welding (FCAW)

Most commonly referred to as MIG or Flux-Core Welding; this process can be used on all of the major commercial metals, a wide range of thicknesses, and requires less operator skill than TIG or stick welding.  Welding speeds are higher because of the continuously fed electrode, absence of slag, and higher metal deposition rates.  Whenever possible, GMAW and FCAW are the chosen welding processes utilized in production shops.

Shielded Metal Arc Welding or Stick Welding (SMAW)

This is the most common form or ARC Welding.  A stick or electrode is placed at the end of a holder and an arc is struck between the tip of the electrode and the metal welding surface.  SMAW power supplies are generally the least expensive but are only capable of being used in manual operations.

Gas Tungsten Arc Welding (GTAW)

In GTAW—or TIG welding—an arc is established between a non-consumable tungsten electrode and the base metal.  A shielding gas protects the tungsten and molten metal from oxidation.  GTAW produces high-quality welds on almost all metals and alloys.  It can be controlled down to very low amperages making it ideal for thinner materials.  GTAW can be done with or without filler material, it also has very little spatter and no slag.  Its biggest disadvantage is speed—GTAW is by far the slowest welding process.

TIG welding process
Tig Welding Process

Plasma Arc Welding (PAW)

Plasma Arc Welding is essentially an extension of GTAW.  Both GTAW and PAW use constant-current power sources and a high-frequency source for arc starting.  The primary difference is that the electrode is recessed in a nozzle to constrict the arc.  PAW is generally more expensive than GTAW but it is more tolerant of joint misalignment and can give better penetration.

welding power sources
PAW Welding Process

Submerged Arc Welding (SAW)

In a SAW welding process, the wire is fed continuously with a granular flux material to cover the weld area.  The flux plays a key role in achieving high speed and a quality weld.  Very little weld fume is produced— eliminating the need for fume extraction.  Utilizing granular flux limits welding positions and requires special handling and recovery solutions.

SAW welding process
SAW Welding Process

Select the Proper Power Supply 

Welding power source types are defined by how they modulate electrical currents and what arc welding process is best supported by this modulation:

Direct Current (DC)

A DC power source is a flow of electrons in a single direction through a circuit. In welding, it creates a steadier arc and smoother output. It can be used to weld with a negative ground, or the flow of electrons can be reversed to flow toward a positive ground in reverse polarity.

Alternating Current (AC)

The AC power source is the bidirectional flow of electrons in which the polarity shifts a hundred or more times per second from a negative to a positive ground. Arcs tend to be less stable and welding is harder to control. However, AC welding can break apart oxide formation and allow for purer welding in some processes.

Pulsed Current

This is a form of DC welding in which the current goes from a high peak current to a lower background current at a frequency determined by the operator. This narrows the arc, allowing greater penetration while reducing the effect on surrounding materials. As a result, pulsed current welding is an excellent choice for welding thin metal or performing deep welds on thicker materials.

Pulsed Voltage and Heat

Pulsing GMAW power supplies focus on controlling pulsed voltage and heat applied to the consumable electrode. Controlling the pulsed voltage (heat) and wire feed speed allows greater control over how the wire melts and the rate of deposition. Adaptive pulse GMAW carefully monitors feedback and automatically compensates to keep the arc consistent despite variation by the welder and differences in height and joint location.

 

Additional Items to Consider

Once you have your welding process and the type of power source selected you should consider a few more key items to determine the size including:

What is your Input Power?

Your power source needs to match the type of input power available. The amount of electricity your welding system needs will ultimately depend on the type of power supply you select.

  • Single-phase: 115, 200 or 230 VAC
  • Three-phase: 230, 460 or 575 VAC

Material Thickness

Simply put, the thicker the material the more power required.

Duty Cycle

Duty cycle is the percentage of arc on-time a welding power source can operate in a given period. One of the most common mistakes welders make is under-sizing their power source. It’s important to understand how much amperage your power source can generate at any given duty cycle and ensure it’s MORE than enough to meet your demands.

Understanding the types of welding processes and power supply types is a large undertaking and can be overwhelming but a reliable power source will serve you for many years.

 

About Bancroft Engineering

Our engineers can help you select the best power source for your welding needs! Bancroft offers custom welding systems and a variety of standardized semi-automatic welding equipment in stock such as positioners, Welda-Round rotary welders, seam welders, weld-lathes and much more!

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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 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.

 

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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!

 

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