The integration of robotics into cold deformation processes is revolutionizing the engineering industry, improving quality, precision and efficiency in welding and forming operations.
Robotic welding islands today represent an integrated system in which one or more robots perform automatic welding operations in continuous and programmable cycles, combined with piece handling and positioning systems. These robots can carry out MIG/MAG, TIG or resistance welding with high precision, adapting to different geometries and treated materials, including special alloys.
MIG/MAG welding
Si tratta di un processo ad arco elettrico che utilizza un filo fusibile come elettrodo anodo (polo positivo) e il pezzo da saldare come catodo (polo negativo).
MIG is short for Metal Inert Gas and uses inert gases (such as argon or mixtures of argon and helium) to protect the weld from oxidation. It is suitable for light alloys such as copper and weakly alloyed steels.
MAG instead means Metal Active Gas and uses active gases (e.g. CO2 or mixtures of argon and CO2) which interact chemically with the molten material, improving arc penetration and stability. It is suitable for unalloyed and weakly alloyed steels.
MIG/MAG welds are versatile, fast and suitable for different metals such as steel, stainless steel, aluminum and nickel; they are widely used in the automotive industry and in the construction of metal structures.
TIG welding
TIG – short for Tungsten Inert Gas (or GTAW – Gas Tungsten Arc Welding), is a tungsten electrode arc weld that does not wear out during the process.
Tungsten, with its high melting point (3380 °C), allows precise heat control and high-precision welding. Ideal for high quality aesthetic and mechanical welding, used in applications such as aerospace, pipeline construction and thin or delicate metals.
The use of robotics in welding ensures constant and standardized quality, eliminating variations related to manual skills and reducing cycle times and production waste. This is especially important for cold deformation, where the joints must withstand mechanical stress without altering the structure of the metal.
1.CONSISTENT ACCURACY
The robots guarantee millimetric repeatability in forming and welding operations, minimizing defects and rework.
2.INCREASED PRODUCTIVITY
Automation accelerates the processing phases, allowing mass production.
3.SAFETY AND ERGONOMICS
The most tiring or dangerous activities are delegated to the robots, thus reducing the risk of accidents for operators.
4.PRODUCTION FLEXIBILITY
Robotic islands can be quickly reconfigured for different products or production cycles, adapting to customization needs.
5.REAL-TIME CONTROL
Advanced sensors and control software constantly monitor process parameters, adjusting force and position to optimize deformations.
Technological evolution introduces collaborative robots – cobots – that operate together with operators, increasing production flexibility and allowing faster and safer interventions. The use of computer vision and artificial intelligence systems also improves the adaptive capacity of robotic cells to varying production conditions.
The integration of robotics into cold deformation processes, via automated welding islands and dedicated robots, is transforming the engineering industry, offering real benefits in terms of quality, efficiency and safety. These technologies, combined with advanced methods such as hydroforming, make it possible to create complex metal components with high mechanical performance and reduced environmental impact, opening up new, highly customized and sustainable production possibilities.
Products EBI is actively part of this evolution, adopting innovative robotic solutions to respond to growing market needs and to consolidate its leadership in the cold metalworking sector.