Elements of a Laser Welding Robot System

A robotic weld cell is a complex combination of other subsystems. Initially, keeping track of the required components can be daunting. So, let’s break this system down into its parts:

The Robot

The welding robot is the central component of the weld cell. Here, the robot refers to the robot's mechanics and controls. Regardless of the type, the robot is responsible for applying the weld. This component both moves and operates the controls of the laser directly. The application requirements should primarily drive robot selection. Robot models feature different design characteristics. When selecting your robot, you should consider ratings like reach, payload capacity, speed, and precision. The application requirements will call for specific performance characteristics that will narrow the types of robots appropriate for your project. We’ll look at some robot selection options in the next section.

The Laser

The laser system is responsible for generating the welding beam. The laser includes the head and the power generator/amplifier, sometimes a separate component. The material and weld requirements help define the laser type required. Be sure to understand which laser best fits your welding application. 

Cooling

Most laser types require a cooling system to function. Lasers generate massive levels of heat. Consequently, this heat can damage internal components. Cooling systems keep laser temperatures within a functional range. Therefore, laser cooling systems are often part of the overall laser package.

Part Presentation

You should consider how you will present the part to the robot for welding. There are often more options available in this area for laser welding systems. This is thanks to the process having a low physical impact on the part during welding. Common options include:

• Conveyors
• Jigs
• Turntables
• Clamps
• Other robots

Sensing/Monitoring Systems

Such a high-tech system comes replete with sensing equipment. Temperature sensors and safety equipment are standard in weld cells. Additionally, beam and seam trackers aren’t uncommon. Suppliers often configure packages with vision systems. These systems can provide a variety of functions. You might prefer different features based on the application. Common applications include:

• Quality control/inspection
• Safety
• Thermal monitoring

Safety

Laser welding is a dangerous application for people. Consequently, it’s essential to implement safety measures to protect employees. Risk mitigation measures commonly include:

• Safety guarding/enclosure
• Light curtains
• Safety scanner(s)
• Lock-out/tag-out systems
• Live-man switch

Laser Welding Robot Types Used Today

A couple of robot types hold a monopoly on the laser welding market. These robots offer the functionality required to automate a laser welding task. However, their differences are significant. Understanding these differences helps you know which is suitable for your application.

Six-Axis Robots

Six-axis robots offer a great mix of speed, reach, payload capacity, and reach. These robots can cover the vast majority of laser welding applications. They excel in small to medium-sized welding tasks. Their excellent range of motion helps them weld complex part geometries.

However, the six-axis robots’ shortcomings can limit their compatibility with larger jobs. For example, their reach is limited to a meter or two. Unfortunately, this is the case even for the biggest robots. However, manufacturers can reduce this shortcoming with the help of an RTU. A robot transfer unit (RTU) extends the reach of your six-axis robot. However, this is an expensive piece of hardware. In addition, RTUs carry separate integration costs and considerations. 

Additionally, robots will have an upper limit to their payload capacity. This limits their ability to handle the enormous lasers required for some tasks. Unfortunately, you can’t mitigate this limitation without a more robust or different robot type.

Gantry Robots

Gantry robots provide nearly unlimited capacity for laser welding. Suppliers can configure gantry robots to handle the largest applications. Additionally, their superior mechanical rigidity allows them to move the biggest lasers. Furthermore, their simple design enables gantry robots to achieve unmatched levels of precision.

These benefits don’t come without drawbacks. Gantry robots are limited in their ability to handle complex parts. Six-axis robots are better designed for tasks demanding high dexterity. Their multi-jointed construction allows them to excel in such applications.

Types of Laser Welding Robot Suppliers

Now you have a grasp of the fundamentals of robotic laser welders. Your next likely step is to research potential suppliers. There are many options in the robot welding market. Let’s cover some common supplier types. This clarity allows you to categorize suppliers in your research. Ultimately, understanding which supplier is right for you can make integration a smooth process.

Robot Manufacturers

Robot manufacturers design, build and sell robots. Most manufacturers cover a broad range of applications and industries. Some even have unique models optimized for welding in mind. Benefits of purchasing directly from the manufacturer include:

• Direct access to the best engineering support
• Preconfigured options
• Engineered solutions
• Best training access
• Great for standard applications

Integrators

Integrators are 3rd party solution providers. They’re typically official channel partners of at least one robot manufacturer. Integrators tend to have broad access to other lines of equipment tangential to the robot system. Benefits of working with integrators include:

• Often provide the best local support
• Highly flexible for custom solutions
• Commonly offer a variety of services outside of robotics

System Solution Providers (OEMs)

System solution providers supply off-the-shelf robot packages. These preconfigured systems are purpose-built for a specific application. There are often variations of these packages to cover a broad range of application requirements. Benefits of working with these suppliers include:

• Cost-efficient overall
• Usually built with unique features
  • Ease-of-use
  • Compatibility with other systems (industry 4.0)
• Quick integration
• System training

How to get started?

Considering automating your laser welding process? Here are some things to think about:

• Assess feasibility Consult with relevant experts to determine if it's technically viable to automate your specific process – and to what degree.  
• Evaluate the benefits Analyze the potential advantages and financial gains from automating the process and weigh these against the investment required.  
• Research solutions and vendors Explore the robot and automation solutions available on the market and identify relevant suppliers. Understand how their capabilities match your needs and evaluate the pricing of different options. 

How we can help

As vendor-independent advisors, HowToRobot can help you assess these factors and make informed automation decisions. With access to over 16,000 robotics and automation suppliers, we know the market and can help you find and compare solutions tailored to your needs.

→ Looking for expert advice? Explore our advisory services and connect with us to discuss your automation needs.

→ Ready to find the right robot and automation solution? Share your project details. We’ll help you scope requirements, connect with vetted suppliers, and receive a range of custom offers.

Whether you're just beginning to explore automation or ready to implement a solution, making informed decisions now can set the stage for long-term success. We're here to support you at every step.