Weld Smarter, Not Harder With Welding Automation Technologies

By Brad Whipple 

The skilled labor shortage is not a new concern within the welding industry. While efforts are being made to attract new talent, those who join still need ample time to learn and truly refine their skills. Because of shortages and the lengthy on-ramps for newer welders, some operations may still be behind in meeting the demands of their business and struggling with weld quality and consistency issues.  

Advanced welding technologies, such as robots or cobots, have helped provide some much-needed relief. Yet, depending on the size of an operation and the number of welding automation cells, the skilled labor shortage can still be a pressing issue due to the limited availability of weld techs and engineers to manage multiple systems. This type of shortage creates challenges in diagnosing and resolving issues like torch misalignment, unplanned downtime and weld defects.  

Automation can help, with solutions that help bridge the gaps by simplifying diagnostics, enhancing equipment durability and reducing the need for highly specialized oversight. These innovations allow operators to manage and maintain welding operations more effectively so that manufacturers stay productive. 

 Use Automation-enhancing Software to Schedule Downtime

Unplanned downtime is a major production issue in automated welding environments, where even a few minutes of halted operations can result in significant financial losses. It also disrupts production flow and often forces teams into reactive, high-pressure situations to get systems back up and running. 

To address this, specialty software solutions have been developed that monitor key welding parameters such as amperage, voltage and wire feed speed in real time. These systems can detect operational anomalies that signal potential failures and alert operators in advance, allowing them to align maintenance with planned downtimes rather than in the middle of production.  

A torch maintenance module is another good option. Available on newer robotic welding torches, such as the Tregaskiss® Atlas™, this device attaches to the gun and provides visual cues as to the health of the torch. A green light indicates that everything is working as it should, whereas a red light indicates that maintenance is required soon. This feature helps reduce torch downtime by up to 87%, keeping maintenance costs low and productivity high. 

Leveraging these proactive approaches to planning maintenance not only minimizes operational chaos but also helps preserve efficiency and reduce costly interruptions during production.  

 Maintain TCP Repeatability with Additional Programming 

Tool center point (TCP) repeatability is critical in robotic welding because deviations as minor as one millimeter can lead to off-seam welds. Several factors can cause TCP misalignment, including standard mechanical wear, part fit-up inconsistencies or accidental impacts to the torch (e.g., it was bumped and is now misaligned from the original position). TCP misalignment can result in defective parts that may not be detected until it’s too late in the production process — causing productivity (and profit) to come to a standstill as the automation is checked and reprogrammed and/or parts are reworked.  

To address these challenges, manufacturers are turning to add-on technologies that enhance TCP consistency. Many robot OEMs offer supplemental software packages that enable the robot to verify and recalibrate its TCP using fixtures like L-brackets for accurate weld placement. It works by having a wire that sticks out of the torch, and the robot is programmed to know where the L-bracket is. The robot will move to the point where the TCP is supposed to be, and if the wire makes contact with the plate, it creates an electrical circuit, sending information back to the software system confirming that it’s in position. Then, it moves down the plate and verifies the full coordinate system by touching different points along the L-bracket.  

Conversely, if the robot moves to the point where it thinks the bracket is and the bracket isn’t there, it won’t get that signal and will continue moving until it makes contact. The robot will then register how much distance it traveled before establishing contact and offsets the whole TCP measurement by that distance, resulting in a weld that’s correctly placed. 

There are other advanced diagnostic tools that can also assess robot accuracy. Through a series of measurements and movement assessments, the specialized software will identify deviations and failing componentry before operational impact becomes too severe. These automation innovations further maximize up time, deliver more consistent weld quality and facilitate a reduction in rework caused by TCP drift or automation malfunction.  

 Keep Spatter in Check with Simple Solutions 

MIG welding is always going to generate some amount of spatter, but excessive buildup within an automation cell poses significant setbacks to productivity and equipment longevity. As spatter accumulates over time on torches, fixtures and tooling, especially in robotic cells that run almost continuously for months, the buildup can impact equipment performance, increase maintenance needs and eventually force extended shutdowns for deep cleaning and repair. Cleanup of this magnitude often involves pricey third-party services that use dry ice and industrial vacuums to freeze off the buildup and clean up the cell. 

To mitigate these effects on consumables, operations can use an anti-spatter spray that reduces adhesion and makes it easier to clean components. The addition of reamers automates removal of spatter from torch consumables and applies a controlled amount of anti-spatter fluid. While some may think “more is better,” in this case, the opposite is true. Excessive spray can drip into the weld puddle and onto the surrounding components, potentially compromising weld quality and equipment performance. The goal is to apply just enough so that it creates an effective but thin layer that prevents spatter from sticking. Additionally, newer robotic welding torches, like the Atlas, feature aluminum covers (versus the traditional plastic) that resist spatter bonding and help maintain equipment integrity and functionality.  

While not a technological innovation, the combination of using anti-spatter spray, reamers and more spatter-resistant materials can help keep big-ticket automation equipment in peak working order for as long as possible, which is important at such high investment levels.  

 Amplify the Use of Your Automation  

Automation has become an essential solution for welding operations, helping manufacturers address persistent concerns such as labor shortages, production inefficiencies and quality control issues. To fully maximize its potential, companies are increasingly adopting supplementary technologies to enhance reliability and reduce downtime. These innovations not only support the core benefits of automation but also create a more resilient and efficient production environment, ensuring that welding operations can meet the demands of today’s fast-paced manufacturing landscape. 

Brad Whipple is a senior engineer for Tregaskiss. Email brad.whipple@tregaskiss.com.