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One of the biggest breakthroughs in modern industrial manufacturing is robotic welding which not only increases productivity, but also plays a key role in ensuring quality. But what exactly is robotic welding, how does it work, and in which industries is it most used? In this article, we present the most important information in detail and how significant the role of sheet metal processing and metal structure manufacturing .

What is robotic welding?

Robotic welding is an automated manufacturing technology in which industrial robots perform welding tasks. These robots can be programmed and use various welding techniques (e.g. arc welding, spot welding, laser welding) can be applied. Robotic welding works with high precision and repeatability, thereby minimizing human errors.

Advantages of robotic welding

• Precision and quality: Industrial robots are capable of extremely precise movements, creating smooth and high-quality weld seams .
• Speed: Robots are faster than manual welders, especially when dealing with a high volume of repetitive tasks.
• Cost-effectiveness: Although initial investment costs may be high, in the long run, productivity gains and reduced errors can lead to significant savings.
• Safety: The use of robots reduces human exposure to hazardous work environments such as high temperatures or welding gases.

How robotic welding works

Robotic welding systems generally consist of the following main components:

• Industrial robot arm: This is the robot’s “hand” that moves the weld head.
• Welding equipment: Includes tools suitable for welding technique (e.g. MIG, TIG or laser).
• Control system: A unit that programs and controls the robot.
• Sensors and cameras: To ensure automatic fault detection and precision.

Where is robotic welding used?

• Automotive: In the automotive industry, it is often used for spot welding (e.g. joining body parts) and arc welding (e.g. manufacturing chassis parts).
• Metal industry: In the manufacture of structural metals, pipelines and tanks, where heavy-duty and precise weld seams are required.
• Mechanical engineering: For the manufacture of industrial equipment and parts for large machinery.
• Aerospace: For welding tasks that require high precision and reliability.
• Electronics industry: For welding small, precise components such as battery cells.

Application of robotic welding in the metal industry

Robotic welding In many areas of industry, especially in the metal industry, it is an increasingly widespread technology. In the production of structural metals, pipelines and tanks, it is particularly important to create heavy-duty and precise weld seams, which robotic welding systems can provide efficiently and reliably.

Why is robotic welding advantageous in metal structure manufacturing?

Superior accuracy and repeatability

Thanks to the programming of robots, each weld seam is made according to the same standards with minimal error. This is especially important for structural elements and pressure vessels, where the quality of seams is critical.

Increased productivity

Robots can work continuously without human fatigue. This allows the production process to be faster and more efficient, reducing production time.

Load-optimised seams

Robotic welding allows the specific behaviour of the material to be taken into account, thus optimising the strength and durability of seams, which is especially important for pipelines and tanks.

Cost effectiveness

Although the introduction of robotic welding technology requires a significant initial investment, it can be more cost-effective in the long run as the number of rejects is reduced and labour requirements can be optimized.

Safe working environment

The heat, light and gases released during welding work can be dangerous for human workers. Robots take on these hazardous tasks, reducing risks to the working environment.

Spheres of application

Robotic welding supports metallurgical production in many applications:

• Manufacture of structural elements: For example, bridges, building frames or larger machine structures.
• Pipelines: Manufacture of pipelines for the oil and gas industry, where leakproofness of seams is critical.
• Tanks: Pressure vessels, liquid containers or heat exchangers where welding quality affects operational safety and efficiency.

Most common robotic welding technologies

MIG/MAG welding (metal gas arc welding)

This is the most common process, which is excellent for welding steel and aluminum structures. The precise control of the robots enables precise seams to be formed.

TIG welding (tungsten electrode arc welding)

It is mainly used for thinner materials and more demanding seams. It is especially important for stainless steel and special alloys.

Spot welding

It is excellent for joining thin sheets of steel, for example in the automotive industry and tank production.

Laser welding

Extremely precise and fast process that uses a high-energy laser beam. Ideal for complex geometries and thin materials.

Advanced technologies in robotic welding

• Automatic seam tracking: The robot uses sensors to monitor the seam position and correct the weld path.
• Artificial intelligence and machine learning: Robotic welders are increasingly able to learn from repetitive tasks and improve seam quality.
• Remote control and monitoring: Operators can monitor the welding process in real time and intervene if necessary.

The introduction of robotic welding in the metal industry not only increases productivity, but also makes it possible to perform precision jobs that were previously difficult to perform.

Concluding thoughts

Robotic welding in the metal industry It has been given an outstanding role, as it not only increases the efficiency of production processes, but also raises quality to a higher level. In various sectors of the industry – be it structural components, pipelines or tanks – robotic welding provides the precision, reliability and strength required to produce safe and durable products.

Robotic systems Due to its continuous operation, repeatability and reduction of labour demand, they can result in significant cost savings in the long run. In addition, since robots are better able to avoid errors than human workers, continuous optimization and improvement of production processes is possible.

Robotic welding is therefore not just a new technological trend, but has become an essential tool in the metal industry, bringing numerous benefits to both manufacturers and end users. Precision welding, cost-effectiveness, a safe working environment and increased industry competitiveness are all contributing to robotic welding becoming a key player in the manufacturing processes of the future.
If you are looking for a company that is at the forefront of robotic welding, then do not hesitate to contact us. Our company uses the In addition to metal structure manufacturing and sheet metal processing, it is able to help meet the needs of its partners in countless areas.

Edge bending is one of the most commonly used metalworking process, in which metal sheets are bent to a specific angle or shape to meet manufacturing specifications. This technology is key to many industries, producing durable, accurate and aesthetically pleasing metal parts. In this article we explain what edge bending is, how it works and which industries benefit from it.

What is edge bending?

Edge bending in which a metal sheet is clamped between the tools of a bending machine (such as an edge bending press) and the material is then bent to a specific angle or shape. The behaviour of the metal during this process depends on three basic factors:

• The quality of the material: During bending, the metal is subjected to both tensile and compressive forces.
• The geometry of the tool: The shape and size of the bending tool determines the shape of the finished product.
• The bending angle and the compressive force: The right angle and pressure guarantee the desired result.

The precision of the process is of paramount importance, as the end result must be not only functional but also aesthetic, especially in industries where visible elements are involved.

How is edge bending done?

Edge bending process in general modern bending machines which ensure precise movement and power distribution. The main parts of the machines are:

• Upper tool (bending blade) that acts on the material.
• Lower tool (sticker) that supports the plate.

In the operation of the machine, the metal plate is placed between the two tools and the pressure of the upper tool causes the plate to take the shape of the lower tool. The result is a precision-bent metal part.

Use of edge bending in different industries

The versatility of edge bending makes it a preferred method for many industries. Here are some examples:

Construction

In the construction industry, elements made of bent sheet metal are often used, for example:

• Roof tiles
• Gutters
• Ventilation systems

These elements provide durability, aesthetics and ease of installation.

Mechanical engineering

In machine manufacturing, the precise size and reliability of edge-bent parts are key. This includes:

• Engine houses
• Spare parts holders
• Protective covers

Automotive industry

In the car industry, bent sheet metal is essential for the production of bodywork, chassis and other structural components. Bending technology ensures that car components are both strong and lightweight.

Furniture industry

In modern furniture manufacturing, edge bending plays an important role in the production of metal frames, table tops and other decorative elements. The thin, curved metal elements give furniture a clean, modern look.

Electronics industry

Precision-bent sheets are often used in the manufacture of electronic devices such as computer housings or server racks.

What are the benefits of edge bending technology?

• Accuracy and repeatability: Modern machines work with a minimum margin of error.
• Cost-effectiveness: The process is fast and efficient, making it economical even in large quantities.
• Versatility: Metal can be bent into almost any shape, from simple angles to more complex profiles.
• Durability: Curved elements provide structural strength while preserving the integrity of the material.

What machines are used for edge bending?
Edge bending is carried out with different machines, the size, type and control of which depend on the application and the precision required. The most common types of machines and their characteristics are described below.

Edge bending presses

Edge bending presses are the most common machines for edge bending. They can be mechanical, hydraulic or CNC controlled.

Hydraulic edge bending presses

• Operation: Hydraulic cylinders move the upper tool (blade) to bend the plate.
• Benefits: They provide high compressive force, making them suitable for bending thicker sheets. They allow even and precise bending.
• Usage: Ideal for machining larger workpieces or industrial-sized sheets.

Mechanical edge bending presses

• Operation: Mechanical energy transmitted through a rotating shaft bends the disc.
• Benefits: Simpler and faster operation, less maintenance.
• Disadvantages: Not as powerful as hydraulic machines, so used for thinner materials.

CNC edge bending presses

• Operation: The bending process is automated by computer control, the machine works exactly according to the parameters set.

• Benefits: High precision and repeatability.
• Even more complex shapes can be made quickly and flawlessly.
• Efficient programming in mass production.
• Usage: Manufacture of electronic enclosures, automotive and machinery components.

Live bending machines (free benders)

These machines are used for bending small to medium sized workpieces where high compressive forces are not required.

• Manual edge benders: Used in small workshops for simple and quick bending. Ideal for thin sheets and small quantities.
• Electromechanical edge benders: These machines are motor-driven, allowing more precise and faster bending than manual versions.

Roll bending machines

Although not specifically edge benders, roller machines can also be used to make simple bends, for example to create curved or cylindrical shapes.

Three- or four-reel versions: They can create a variety of shapes and curves that are not limited to flat bends.

Panel folding machines

Special edge bending machines that automatically bend sheets from several sides. They are mainly used to produce complex box shapes and framed parts.

• Benefits: High precision. Ability to produce complex bending patterns.
• Usage: Electronics and furniture industries where complex, multi-sided bending is required.

Robotic edge bending systems

Automation is becoming more and more important in the industry, so robotic edge bending systems are becoming more common. These systems use robotic arms to position the plate while the bending machine does the actual work.

Benefits:

• High efficiency in high-volume production.
• It requires minimal human intervention.
• Suitable for more complex parts.
• Usage: Automotive industry, large series production.

Special bending machines

Some industries use specific bending machines for their specific needs, for example:

• Tube bending machines: Although not specifically edge benders, these machines are used to accurately bend tubes and profiles.
• Profilers: Used for shaping shaped metal profiles and sheets with special cross-sections.

What criteria are used to choose a machine?

The choice of machine for edge bending depends on the following factors:

• Plate thickness and material: For thicker and harder materials, a machine with higher pressure is required.
• Complexity of the product: For simple shapes, a hand bender may be sufficient, while for more complex profiles a CNC machine is needed.
• Quantitative needs: For large series production, robotic systems and CNC machines are ideal.
• Accuracy and repeatability: If precision fitting of parts is important, CNC or hydraulic machines are recommended.

Concluding thoughts

Edge bending is an essential technology in modern industry, offering a combination of precision, durability and aesthetics. From construction to automotive and electronics, many industries rely on this reliable process. And as the technology continues to evolve, it will allow for even more complex and innovative products in the future.
If you are looking for a for the manufacture of metal structures, for plate tempering, edge bending or possibly laser cutting you need, please feel free to contact us. We have state-of-the-art systems and technologies and we will get the job done quickly, efficiently and with high quality.