6 Benefits Of Automated Stud Welding For Manufacturers

What Is Automated Stud Welding?

Automated production welding is often used throughout manufacturing and construction industries. Production welders join metal pieces often using heat or other fusing methods. Over the years, organizations have adopted production stud welding processes because they offer several advantages over manual stud welding, particularly when multiple welds over a single workpiece (or series of workpieces) need to be consistent and high quality. Today's global industrial sector is more competitive than ever, so manufacturers are looking to reduce costs while maintaining high production standards. Investments in production stud welding systems pay off by providing responses to both those priorities.

In almost all automated welding processes, computerization of controls is an integral aspect of the system. Microprocessing units can enable engineers and machine operators to manipulate welding specifics such as current and arc time to accomplish the specific welding procedure at hand. Those same processors also facilitate quick and effortless transitions from one form of a workpiece to another.

A stud weld gun often conjures the image of a single, handheld model connected to a power source, moving down a workpiece, welding stud after stud. Today's stud welding technology, however, accommodates a broad range of production weld heads, configured in proprietary designs to achieve the best weld under any condition.

The main benefits of production stud welding are significant in themselves, and within each, there are additional benefits related to the type of weld and the varieties of welding materials used.

Top Benefits Of Production Stud Welding

1. Higher Consistency Of Weld Quality

Unlike human welders, automated welding systems do not tire and can produce uniform, high-quality welds consistently over a long period of time. High-repetition actions also are taxing to the human body and can cause chronic physical health issues as well as negatively impact the quality of the job performed. Again, production stud welding eliminates wear and tear on operators' bodies while ensuring an accurate and quality weld every time.

2. Faster Production Times

Even when hand stud welding completes a task in less than five seconds, an automated system can accomplish it faster. Experts estimate that a production welding line can produce twice the work of a human welder in the same amount of time, doubling the value of the project. Increased welding speeds ensure that the welding projects do not slow down the overall manufacturing process, and the high quality of the welds ensures that there will be no stoppages for welding repairs, either.

3. Reduced Labor Costs

Rather than pay highly skilled welders to make these assembly-line-type welds, those welders' services can be better used on more sophisticated and complex projects. Production stud welding frequently requires the less demanding skill set of a machine operator to set the controls and oversee material feeds and other welding processes. In some communities where skilled welders are in short supply, a production stud welding line can provide many of the same services at a lower cost and with potentially better results.

4. Automatic Stud Feed

An automatic feed speeds up the production process significantly because the welding process can only go as fast as the studs are made available. Manually feeding the welding gun takes time and is affected by the style of the tool and the dexterity of the welder. Manual feeding the gun might result in up to 10 welds per minute. Automatic feeders, however, are designed to produce a stud as fast as the tool completes the last weld.

The length of time for a weld to be complete is usually under two seconds; an automatic feeder will have the next stud ready as soon as the prior weld is finished. Speedy feeding of the equipment makes using a production stud head more efficient and economical. These systems are more complex in that they have feeding systems (typically a bowl feeder) and control systems to coordinate the operation of the bowl sending a faster and the weld head receiving a fastener.

5. Programmable Controls and Fixed Automation

Another benefit of a production stud weld configuration is the programmable controls that can be a part of your welding process. By adding fixed automation (air cylinders and actuators), the operator can load the workpiece, load the fastener (in the case of hand load), and press palm buttons. The PLC takes over and positions parts, clamps parts, lowers the weld heads and initiates weld sequences. This can all be done to improve accuracy and increase production speed.

6. Data Reporting

Today's digital technology has transformed the welding industry by providing accurate, per-weld data on every run. Digital controls can be set for any type of fastener and any type of base material, automating the entire welding process. Additionally, some controls will also report the date and time of the work, the weld tools used, the weld parameters, and results. Quality control documentation features provide reliable reports on each weld.

Speak With Image Industries About Production Stud Welding

There are several crucial factors to take into consideration when selecting a welding service to handle your welding requirements. Quality and experience are by far the most critical factors. In today’s manufacturing environment, production capacity and the ability to meet deadlines are essential.

If you're considering acquiring a stud welding system, there are production weld head systems that might work well for your needs. Contact Image Industries today to learn more about production stud welding systems.