Category Archive: robotic welding

When To Use Robotic MIG Welding

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MIG welding, also known as Gas Metal Arc Welding (GMAW), is a popular welding process that uses a continuous wire feed as the electrode. It also utilizes an inert shielding gas to protect the weld from atmospheric contamination.

With the constant innovation of welding automation, robotic welding has become a viable option for many manufacturing processes. Particularly, robotic MIG welding offers several advantages over traditional manual processes, such as improved efficiency, increased productivity, and reduced labor costs. However, it may not be suitable for every application.

This article will discuss the best applications for this welding technology.

Ideal Applications for Robotic MIG Welding

Automated welding has gained popularity across different industries, and there are situations where robotic welding technology is most suitable. Below are the ideal applications for robotic MIG welding:

Large Production Runs

Robotic welding systems are highly effective for high-volume production because they provide uniform, high-quality welds at a significantly accelerated pace. They also decrease the dependency on human labor, which can lead to shorter production times and cost savings. This makes them an ideal option for industries that require a large volume of welds to be produced promptly and efficiently.

Difficult Welding Positions

Robotic MIG welding is well-suited for challenging positions like overhead or vertical welding. These positions can be extremely difficult for human welders, but machines can easily reach and weld these areas. Additionally, robots can maintain a consistent welding speed and angle, which can be difficult for manual workers.

Repetitive Welding Tasks

With robotic welding systems, manufacturers can automate the process and program the robot to perform the same welding task repeatedly. This ensures consistency in weld quality and reduces the likelihood of human error. This consistency is also particularly important in industries where high-quality welds are critical to the performance and safety of the finished product. Examples of industries and sectors include aerospace, automotive, and medical device manufacturing.

Repetitive welding tasks can also be tedious and physically demanding, leading to human error and fatigue. Robotic systems can help manufacturers reduce the risk of injury, improve weld quality, and increase productivity.

Welding in Hazardous Environments

Robotic systems can be a safe alternative for welding in hazardous environments, such as nuclear facilities or chemical plants. Robots can be programmed to perform welding tasks remotely, eliminating the need for human welders to enter dangerous areas and minimizing exposure to harmful substances. They can also be equipped with sensors that allow them to detect and respond to changes in the area.

Complex Part Geometries

In industries where complex shapes and intricate designs are common, robotic welding is a game-changer. Robots can move in multiple directions, angles, and positions and can be programmed to weld complex shapes precisely. This ensures consistent weld quality and eliminates needing specialized welders with advanced welding skills.

Dissimilar Materials

Welding non-traditional materials — such as aluminum, stainless steel, and titanium — can be challenging using traditional methods. These materials have different chemical and physical properties, melting points, and thermal conductivities. With robotic welding, manufacturers can customize and adjust the welding parameters to match the specific requirements of each material.

Choose Ohio Valley Manufacturing for Your Robotic Welding Needs

At Ohio Valley Manufacturing, we pride ourselves on being a one-stop shop for all your robotic welding needs! Our services range from designing and building welding fixtures to producing and verifying welded parts in-house. We also have a state-of-the-art facility that handles high-volume automation, making us an ideal partner for companies looking to streamline their processes.

Contact us today to learn more about our robotic welding services and how we can help take your production to the next level!

Understanding the Benefits of Robotic Welding in Manufacturing

Automation has become the latest buzzword in business – especially in the manufacturing space. It can mean different things to different people, but overall, it comes back to artificial intelligence. For manufacturers, shop floor robotic systems are the very definition of automation.

Incorporating robots into the production line has a number of benefits. At Ohio Valley Manufacturing, we have the advantage of in-house robotic welding capabilities. This extends from the design phase through production and inspections. Having robotic systems available to take care of welding and stacking products cuts down on time and money. It also saves our workers from ergonomic challenges from repetitive movements and heavy lifting.

By automating these processes, our employees can take on higher level jobs within the company without sacrificing production demands. As a result, we’re able to eliminate specific labor costs and improve efficiency throughout our operations.

This entire process is able to lower costs for our customers by reducing our own operating costs. It also allows us to take on more high-volume orders without sacrificing quality or on-time deliverability.

We currently serve a variety of industries, including on and off-highway trucks, material handling, outdoor power equipment, agricultural equipment, petrochemical, and more. Our welding capabilities include MIG welding, projection welding, resistance welding, spot welding, Flux Core Arc Welding, and others.

Having the robotic welding assistance offers the flexibility and efficiency needed to complete each customer’s order. Our highly trained technicians are also available to provide free hand welding when required.

Our goal is always to provide the highest level of quality and service for every job. By incorporating robotic welding in our process, we are further able to provide the best value for these projects.

To learn more about our capabilities and past projects, feel free to contact us for additional information.

Welding: MIG Versus TIG

Welding is a core component of metal fabrication. It is the process of joining metals using a fusion process where the base metals are melted together using a filler material to form them joint. This is a high-temperature process and can be performed by hand or through robotic welders.

Two commonly used welding methods are known as TIG and MIG. The final outcome for both joins metals together but the processes and material are different and there are advantages and disadvantages to both. In this post we will look at each method’s pros and cons.

TIG welding or Tungsten inert gas process that uses a non-consumable tungsten electrode to make the weld. TIG comes from Tungsten, Inert Gas and the weld area is shielded from atmospheric contamination by a gas such as argon or helium. TIG welding requires the welding rod to be slowly fed into the weld puddle.

MIG welding or metal inert gas uses a gun to continuously feed the welding wire into the joint to burn, melt, and fuse the pieces together. Atmospheric contamination is prevented by flowing an argon-based shielding gas or an argon-carbon dioxide mix over the weld puddle.

Let’s compare the two methods:

Cleaner, less fumes and sparks More sparks and fumes
Less contamination, higher precision
Good for thin material, can be used with no filler Welds a wide range of material
Longer setup, not user-friendly Less setup, easier and more forgiving welds
Welds cost more and take longer More accessible equipment reduced costs
More complex and requires more skill Easier to learn and makes quicker welds
Can weld many different types of metals Most often used with carbon steel, stainless, aum

At Ohio Valley we provide in-house welding services that cover all projects from design and building to checking fixtures and production. Using material handling robots enables us to offer a cost effective solution and we are equipped to handle high-volume automation.

Contact us today to learn about Ohio Valley’s robotic welding service and TIG vs MIG welding operations.

Ohio Valley Holiday Traditions Blog

It’s hard to believe that it is holiday time already. The past year has gone by so quickly! At this time of year, we have traditions that remind us of the spirit of the season and how important it is to find some time to enjoy!

Our employees know that Thanksgiving wouldn’t be complete without the centerpiece turkey. We buy and give turkeys to each employee for their family meal. This holiday tradition is one of the ways we show our appreciation for all the hard work and dedication our employees give to us throughout the year.

Another fun holiday tradition is the annual Christmas Party! The machines shut down, and the music is cranked up for a few hours so that everyone has a chance to mingle, visit, and catch up with each other. Over lunch and holiday treats, we all relax and give thanks for the blessings of the past year and to plan for the year to come. It is a fun way to celebrate Christmas and each other!

We couldn’t be successful without the dedicated staff who work with us. From the old timers to the younger staff, each employee brings experience and expertise to the job and is valued and appreciated all throughout the year. Because of them, we are highly regarded in the industry and are one of the top suppliers in the country.

From all of us at Ohio Valley Manufacturing to you and yours, we wish you the Happiest of Holidays!

Ohio Valley Manufacturing’s Robotic Welding Services

At Ohio Valley Manufacturing we started with a focus on heavy gauge stamping and have grown over the years to offer our customers an array of services, including our robotic welding services. Our services include everything from the design and building to checking fixtures and productions. By using a robot to automate the welding process we are able to improve efficiency, reduce labor costs, and offer our customers a cost-effective welding solution.

We use a free hand robotic welder that is equipped to handle high-volume automation and is ideal for manufacturing on- and off-highway truck parts, trailer parts, outdoor power equipment, material handling equipment, agricultural equipment, automotive parts, and petrochemical equipment.

We are equipped to handle MIG (Metal Inert Gas), Projection, Resistance, FCAW (Flux Core Arc Welding), and Spot welding and can create parts from a variety of materials such as carbon steel, aluminum, copper, nickel, titanium, stainless steel, and more.

To find out more about our robotic welding services and to view examples of our work, visit our website. We also post more industry news and company updates on Twitter and LinkedIn pages.