Feasible Alternative: Fabricators can bridge the skills gap with tools designed to make welding with a robot or cobot easy
 Above: New technology in sensors and cobots make lower volume and less repeatable parts new targets for automation. 

January, 2025- Experts predict that 2025 will see a seismic shift in the robotics landscape. Markers point to increased use of collaborative robots, advanced AI integration, greater focus on service robots and development of humanoid robots with greater dexterity.

In as little as five years, consumers can expect to see approximately 20.8 million driverless cars on U.S. roads. Despite the potential of these and other disruptive technologies, there remain a number of technical and practical challenges to overcome.

“Automation has been heavily adopted by automotive companies since the 1980s, with other larger manufacturers jumping in through the early 2000s,” says Joshua Leath, senior product manager for Yaskawa America Inc. “What we have seen over the last decade is a growing demand  especially among smaller companies for robotization designed for ease of use. Companies need to be able to be competitive but they can’t do it without skilled help. The feasible alternative is robots.”

GOALS

According to Leath, automation can be broken down into three broad categories. Industrial robots typically serve as dedicated systems designed to process the same part repeatedly. Low code methodology refers to a software development approach that uses visual interfaces and pre-built components to support rapid creation and deployment of applications and workflow without the need for advanced or proprietary coding skills. No codes such as AI are best suited for manufacturers with high mix/low volume requirements. Human intervention is minimal in an AI-driven application.

With lead-to-teach and less protective barriers thanks to integrated force sensors, cobots can be easier to teach than traditional industrial robots.

Yaskawa Motoman has been working in the eld of automation for more than 35 years. An industrial robotics specialist, the company has installed more than 600,000 Motoman industrial robots, 25 million servos and 35 million inverter drives worldwide. Technicians match customers with the right automation option by listening to their job requirements.

“It really boils down to a customer’s automation goals,” says Leath. “For example, the best solution for someone who wants to improve quality will look different from someone who wants to augment their limited workforce with an industrial robot.

A customer who has a high mix of parts and a lot of different welds would want to consider a collaborative robot. “Our conversations with customers often start with cobots,” he says, “because they are easier to understand. But a large majority still use industrial robots for higher potential throughput particularly those who already have industrial robots and are continuing to deploy new products.”

Larger corporations typically are able to bear the cost and implementation of traditional automation, but smaller shops, which make up 75 percent of America’s 250,000- plus manufacturers, continue to search for flexible automation that is easier to use and to program. In particular, Yaskawa is seeing an uptick in demand for robotic welding systems as the shortage of skilled human welders surpasses 400,000.

Yaskawa’s new Weld Builder application on its Smart Pendant provides step-by-step instructions to allow any welder to program a robot without prior experience.

To help fabricators bridge the gap, Yaskawa introduced a new product at Fabtech 2024. Weld Builder makes welding accessible to personnel not familiar with the skill set. The product will be available as an application on Yaskawa’s Smart Pendant early this year.

“Yaskawa’s roots are in welding,” says Leath. “Weld Builder is supported by the Wizard tool, a software guide that leads the operator through the welding process step by step.” The company developed the Universal Weldcom Interface to be fully compatible with any robotic power supply source. “We looked at market needs across the board and evaluated how we could make welding an easier task to approach without sacrificing quality and flexibility,” he says.

NEW TOOLS

Weld Builder, the Wizard software and the Universal Weldcom Interface can be used together on an industrial robot or a cobot. A user enters variables such as metal thickness, metal filler and gas and Weld Builder suggests the optimal weld process. If an operator has welding experience, Weld Builder will allow the user to change variables and parameters for the application. The Universal Weldcom Interface provides the digital connection between the robot and the power supply and generates the suggested weld processes that Weld Builder provides to the operator. Our conversations with customers often start with cobots. Joshua Leath, Yaskawa America Inc.

Yaskawa field tested Weld Builder at Fabtech by handing the pendant to booth visitors to use. “We wanted to see what people could do with it,” Leath says. “Everyone was able to use it by following the Wizard prompt."

Cobots feature power force limiting sensors and can be integrated into areas used by human welders, minimizing the need for costly, expansive safeguarding.

CAREERS

Yaskawa Motoman develops products with an eye toward attracting young people to the trades. “We want to even reach students as they decide on career paths,” he says. “Ease-of-use tools make that possible. If I can show someone how to move a cobot around, then they can apply their career skills, such as welding.”

Initially, Weld Builder will be available for “point A to B welding pretty straightforward pieces.” It will also be able to handle thinner materials, 1/8 in. up to ½ in., says Leath, indicating butt joints, T-joints and fillet welds, which make up a majority of welding applications.

“We are currently working on additional adaptive welding tools for Weld Builder to be released in the future that will allow job shops and fabricators to perform more complex welding applications.”

Cobots feature power force limiting sensors and can be integrated into areas used by human welders, minimizing the need for costly, expansive safeguarding.

Yaskawa America Inc., 937/847-6200, yaskawa.com.