Automated production lines are widely used in the automotive and industrial markets and provide several advantages for manufacturers. As companies continue to realize the need for automation to remain competitive, robotic systems are becoming increasingly more advanced. So, why should stud welding be left behind?
By implementing an automated production line for stud welding in vehicles and light industrial manufacturing, it’s possible to boost efficiency and output without compromising quality.
Automated production line
The stud welding process, which has many applications in the manufacturing of steel products, is generally segmented into multiple production stages to manufacture a variety of steel components — which helps to streamline the process. This can help to improve the accuracy and quality of the welds, reducing the amount of time it takes to complete the process, thereby improving efficiency in your manufacturing operations.
Automated processes can also make factories safer by reducing the amount of human intervention required on production lines with heavy equipment and hazardous materials.
Automated stud welding processes are typically used in large-scale manufacturing projects where a material handling system can manipulate sheet metal components. This is typically done in two ways with stud welding equipment: The most common is to mount the welding equipment on a robot that moves the tool to the welding position on the part. The alternative practice involves fixing the welding equipment in place and moving the part to the welding position.
Both methods require the automated weld head to be in close proximity to the welding position on the part, and motionless before initiating the welding process.
The weld process is exceptionally quick and is called “Split Second Fastening”, since the weld times are usually less than 100ms. After the weld process, the equipment will feed another stud to the weld head to prepare for the next weld, this can be done while the robot moves its position, or the material handling is moving the part, to optimize the cycle time.
Integrated stud welding systems
To enable quick and efficient stud welding, you need the right equipment. STANLEY Engineered Fastening, which offers a diverse portfolio of fastening products, provides a broad range of tools, studs, accessories, and services to automate stud welding process.
STANLEY Engineered Fastening’s stud welding system from Tucker uses the no-hole fastening method. In this process, the stud is welded onto the car body, or customer part, using the drawn arc stud welding process. With no-hole fastening the customer’s part will not need to have holes drilled, which minimizes the risk for corrosion and leaking. Another benefit of the process is the welding equipment only requires single-side access to the part when welding.
The new generation of Tucker stud welding equipment allows for easy, reliable, and energy-efficient no-hole fastening on a unified platform. These tools are equipped with linear motor technology to enable accurate positioning. Their high operational reliability and compact design give manufacturers a definite advantage in the production of large and small steel components.