This is an excerpt from an article published on Fab Shop Magazine written by Mahyar Asadi
On the path to welding automation, there is an important role for human welders to fulfill. Machine learning has improved the overall task of robotic programming while evolving technologies are enabling new automation that allows robots to be trained to adapt in real time. But there are situations when humans are needed – be it navigating variable gaps or tacks or preventing bad welds and halts in production, robots can’t do it all.
Fit-up variation, joint distortion and tacks all present challenges for welding automation. That’s when the integration of human expertise is a required input in the automation process. According to Len Zapalowski, vice president of business development at Novarc Technologies Inc., the ability for a human to intervene in robotic welding is still crucial in a variety of scenarios.
Hazardous areas
“Traditional robotic welding in hazardous areas still requires the input of the welding engineer who has the capability to alter or control the weld parameters to ensure the robot can perform, despite variable conditions,” Zapalowski says. “In these cases, the knowledge of the welding technician is seen as a big advantage to control the robot.”
In environments such as the nuclear industry or where high levels of PPE are needed due to extreme heat, cramped spaces, or dirty and hazardous conditions, human welders cannot be physically on the job for certain periods of time. In these and many other environments, there is a need for collaboration – where the robot can be exposed to the harsh conditions but a human is required for their adaptability and experience.
New technologies, such as Novarc’s NovAI Control, combine the autonomy of robotic welding with the expertise of human welders. With the flexibility to be deployed in new and existing welding cells, NovAI Control allows a welding engineer or operator to provide input remotely, enabling the robot to work in varied and challenging conditions where traditional robotics would fail.
This also applies to very large components or structures where remote control is invaluable for safety and precision during early weld development. Remote welding increases safety by allowing operators to perform difficult welding tasks while minimizing their exposure to hazardous environments, including extreme heat, fumes and high-risk areas.
Commissioning, startup
Clearly, there are several applications where a collaboration of both humans and robots are needed for welding success. But there is also a major need for human expertise long before any welds are laid. During the initial development of welding paths and procedures, remote input from an experienced individual is a significant advantage. This allows for real-time adjustments and the incorporation of human knowledge during early weld development, ultimately improving the final robotic weld.
“During any commissioning or startup of any welding processes, there is an opportunity to use human input in the development of the welding path and procedures,” Zapalowski says.