Enhancing Metal Fabrication Processes With Cobots

Collaborative robots (cobots) help metal fabrication processes ranging from measurement and layout to cutting and welding. Metal fabrication businesses can program them to connect with existing computer systems and robots to streamline automation. These collaborative robots are also equipped with features like smart sensors to increase accuracy and safety.

Read on for more information on cobots in manufacturing and how cobots can help metal fabrication businesses boost productivity and outputs. Learn the strategies involved in each step of integration, from preparation to maintenance.

Characteristics of Cobots

Cobots are programmed to execute complex projects using a robotic arm, supporting tools and a programming interface. They are fundamentally different from traditional robots.

Traditional robots work separately from human activities, take up larger spaces and require sufficient downtime to reprogram. Cobots are programmed to safely share a workplace with humans, making workers’ duties less stressful. They’re also easier to program for new functions and are compact, allowing for improved space practicality.

Advantages of Cobots for Metal Fabrication

Cobots can assist with many tasks involved in metal fabrication, from cutting and forming to extrusion and welding. They offer several benefits for metal fabrication companies, such as:

• Boosting productivity: Cobots can perform repetitive tasks with precision, often more quickly than human workers. Manufacturers report productivity gains of 50%-300% when using cobots. Employees can focus on more urgent and complex jobs, and companies can increase profits during busy seasons by taking on more work and clients.
• Managing labor shortages: When qualified welders aren’t available, cobots can help businesses pick up the slack and lessen the load on an under-staffed team.
• Reducing costs: While cobots require a significant upfront investment, they’re more cost-effective in the long run. They allow your human workers to focus on more intricate tasks while handling mundane ones. That means faster processes, allowing companies to do more work and increase profits.
• Increasing consistency in precision: Cobots can be programmed to complete precision tasks consistently, while human welders can cause irregularities. This benefit results in more consistently accurate welds with repetitive tasks.
• Improving safety: Cobots come with sensors that can detect people or objects in their vicinity. This feature allows them to reduce their movement speed or shut down to prevent collisions, resulting in a safer work environment.

Strategies for Integrating Cobots Into the Metal Fabrication Process

Integrating cobots into the metal fabrication process can boost productivity and morale and save labor costs. They are designed to be simple for employees, requiring minimal additional training and skills. Here are the typical strategies that companies implement in each step of working with cobots:

Cobot Integration Preparation

To prepare, metal fabrication companies must identify where a cobot can be used and determine the appropriate end-of-arm tooling required to master the necessary tasks. They must also ensure their selected size can function safely among human workers without other physical obstructions.  

Businesses can base the decision to integrate cobots into the workforce on risk assessments. Specific tasks may pose occupational safety risks or cause workers to waste effort on repetitive tasks. Cobots can be programmed to perform specific functions that may reduce hazards for workers or boost efficiency by allowing employees to focus on more complex tasks.

An often overlooked step in preparation is informing staff of the benefits of cobots and addressing any anxiety or concerns they may have about their new co-worker. It’s essential that the team is onboard and understands the cobot is there to assist and improve productivity.

Once the company has allocated the proper space, task and safety requirements, they can successfully integrate the cobot into the workplace.

Cobot Programming and Training

Once the cobot is installed, it must be programmed, and staff will receive training.

• Detail the physical steps: Employees physically take the cobot arm through the coordinates of different stages of the required metal fabrication process.
• Outline the input and output: Workers enter each task’s start and end points into the software. 
• Create a task library: The staff repeatedly moves the cobot arm through each stage for different tasks. This step creates a library of programs workers can use for future tasks that could benefit from cobot assistance. 

Unlike traditional robots, cobots aren’t solely dependent on the skills of highly trained programmers. Companies can train them to perform specific functions by training staff to work with specialized programs. The training isn’t extensive, as the user-friendly software makes it easy for workers to ensure precision, safety and accuracy with required tasks. Once programmed, staff only need to select the correct task parameters like feed, speed and values. 

Most suppliers offer training to get staff comfortable with new equipment, ensuring a smooth transition to utilizing cobots in welding tasks.

Post-Integration Maintenance and Support

Conducting regular maintenance and support is crucial to ensure cobot integration runs smoothly without causing significant downtime. Here are the general steps involved in cobot maintenance:        

• Conduct daily visual checks: Staff should have a transparent process for identifying potential issues, such as misconfigured cables and bolts. Reporting and fixing these issues early on can prevent extended downtime. 
• Clean sensors regularly: Cobots rely on sensors and optics to perform tasks accurately and easily move items. Workers should ensure the sensors are free from dirt and dust. 
• Perform software updates: Regular software updates enhance the cobot’s safety features and new operational features, which can make troubleshooting easier in the future. 
• Work with qualified technicians: When the cobot needs repairs, it’s crucial to work with knowledgeable professionals when the cobot needs repairs to ensure safety and prevent further damage. 

The Future of Cobots    

Cobot technology is set to coexist in many industries to help employees work more productively and accurately. It will also bridge the gap in fields with shortages. For example, the American Welding Society highlights that the United States has a shortage of around 400,000 welders, which has a drastic ripple effect on many industries. Cobots can play a crucial role in reducing labor stress in this field and ensuring companies reduce bottlenecks and meet deadlines. 

Cobots can help metal fabrication businesses meet deadlines, boost accuracy and reduce employee stress while increasing orders.

Upgrade Your Output With Cobots From Meritus Gas Partners

Are you looking for cobots to streamline processes in your metal fabrication business? At Meritus Gas Partners, our associates offer cobot solutions that can handle repetitive or complicated tasks with unmatched accuracy and speed. For example, MOD-WELD cobots from APT Manufacturing Solutions have the flexibility and precision to conduct robust welding tasks with a user-friendly interface your staff can integrate seamlessly. 

If you’re unsure where to start, speak to one of our experts today. Feel free to request a quote from us, or find a partner near you to learn more about purchasing a cobot.