quality Industrial Robot Arm & Welding Robot Arm factory

“On the robot must be selected without teaching” ‘fully automated welding = the future of competitiveness’ - the anxiety of the manufacturing industry is being infinitely amplified by the marketing rhetoric. As a deep-rooted welding field for more than 20 years practitioners, I was saddened to see: 60% of the customers in the selection of the early stage of the “technology path dependence”, while ignoring the depth of their own process analysis. This article from the essence of the process, three steps to end the “pseudo-needs”, to find the optimal solution. Welding scene “three-dimensional positioning method”: first know yourself, and then choose the technology Dimension 1: process complexity - the starting point for determining “intelligence”. Simple scene (suitable for traditional teaching robots): ✅ Single type of weld (straight line/ring) ✅ Consistency > 95% (e.g. mass production of automotive exhaust pipes) ✅ ≤ 3 material types (carbon steel/stainless steel/aluminum alloy) ✅ Cost Warning: The payback period for such scenarios can be extended by 2-3 times with strong no-tutorials. Complex scenarios (no teaching value highlights): ✅ Multi-species and small batch (e.g. customized parts for construction machinery) ✅ Workpiece tolerance > ± 1.5mm (real-time correction) ✅ Dissimilar material welding (steel + copper, aluminum + titanium, etc.) ✅ Typical case: after the introduction of a no-demonstration program in an agricultural machinery enterprise, the commissioning time for production changeover was shortened from 8 hours to 15 minutes Dimension 2: production volume - to calculate the “automation” of the economic accounts Formula: Break-even point = equipment cost / (single piece of labor savings × annual output) When the production volume 20,000 pieces/year and the product life cycle is >3 years, the teaching-free solution is more cost-effective. Dimension 3: Environmental constraints - the “invisible threshold” of technology implementation Four major constraints that must be evaluated: ① Workshop dust/oil level (affecting vision system accuracy) ① Workshop dust/oil level (affects vision system accuracy) ② Grid fluctuation range (whether the equipment can work stably under ±15% voltage variation) ③ Spatial accessibility (pipelines/tight spaces require customized robotic arms) ③ Space accessibility (customized robotic arms for pipelines/narrow spaces) ④ Process certification requirements (automotive industry needs to comply with IATF 16949 process specifications) Process selection of the five “fatal misunderstanding”: to avoid 90% of the customer procurement pit Myth 1: “Fully automated = completely unmanned”. Reality: no teaching still need process experts to set quality rules, the blind pursuit of unmanned may lead to a spike in scrap rate Avoid the pit strategy: require suppliers to provide process parameters debugging interface, retain the key nodes of manual review rights Myth 2: “The more functions the software has, the smarter it is.” Truth: Functional redundancy will increase the complexity of operation, a customer purchased “all-in-one” equipment because the operator mistakenly touched the AI button, resulting in batch rework. Core principle: choose a system that supports modular subscription (e.g., purchase basic positioning functions first, then upgrade as needed). Myth 3: “Hardware parameters equal actual performance”. Key indicators disassembled: Repeat positioning accuracy ± 0.05mm ≠ welding trajectory accuracy (affected by torch deformation, heat input deformation) Maximum speed 2m/s ≠ effective welding speed (need to consider the acceleration and deceleration process energy stability) Suggestion: Use the actual workpiece to carry out zigzag trajectory welding, and test the consistency of the depth of fusion at the inflection point. Myth 4: “One-time investment to end the battle” Long-term cost list: Annual fee for software licenses (some vendors charge by number of robots) Process database update fee (new material adaptation requires the purchase of data packages) Four Steps to Scientific Decision Making: A Complete Map from Requirements to Landing Step 1: Digital modeling of the process Toolkit: ✅ 3D scans of welded seams (to assess trajectory complexity) ✅ Material heat input sensitivity analysis (to determine control accuracy requirements) ✅ Welding process evaluation report (to define certification criteria) Output: “Digital Portrait of Welding Process” (with 9 dimensions of scoring) Step 2: Technology Path AB Test Comparison of program design: Program A: high-precision demonstration teaching robot + expert process package Scheme B: Teach-free robot + adaptive algorithm Test metrics: ✅ First-piece pass rate ✅ Changeover time ✅ Consumables cost/meter welded seam Step 3: Supplier Capability Penetration Assessment Soul six-question checklist: ① Can you provide test weldments of the same material? (Rejected generic demo parts) ② Is the algorithm open to process weight adjustment? (Prevent “black box” decision-making) ① Can you provide test weldments of the same material (reject generic demo parts)? ④ Is the after-sales service response time less than 4 hours? ⑤ Does it support acceptance by third-party testing organizations? ⑤ Does it support acceptance by third-party testing organizations? ⑥ Is the sovereignty of data clearly attributed? (Prevent process data from being locked) Step 4: Small Scale Validation → Rapid Iteration 30-day validation plan template: Week 1: Basic function acceptance (positioning accuracy, arc stability) Week 2: Extreme working condition test (large angle climbing welding, strong electromagnetic interference) Week 3: Production beat challenge (continuous 8-hour full load operation) Week 4: Cost audit (consumable loss rate, gas consumption comparison) Conclusion    The end point of welding intelligence is to bring technology back to the essence of the process! When serving a new energy vehicle supplier, we decisively recommended that the robot be retained for the box weld (due to the high consistency of the workpieces), while the non-teaching program was adopted for the shaped joints of the impact beam. This “hybrid intelligence” strategy helped the customer save 41% of the initial investment. Translated with DeepL.com (free version)

I. From CNC system to robot king: the ultimate philosophy of a technology maniac Start-up and core technology breakthrough (1956-1974) In 1956, Fujitsu engineer Kiyoemon Inaba led a team to establish FANUC (Fujitsu Automatic CNC). This engineer, known as the "Godfather of Japanese Robots", once made a bold statement: "The ultimate goal of the factory is not to turn on even a light." 1965: Launched Japan's first commercial CNC system FANUC 220, which increased the machining accuracy of machine tools to micron level and subverted the traditional mechanical control mode. 1972: Independent from Fujitsu, launched the first hydraulic drive industrial robot ROBOT-MODEL 1, specializing in automobile parts handling, and the operating efficiency is 5 times higher than that of manual labor. 1974: A breakthrough was developed in the development of a fully electric servo motor to replace the traditional hydraulic drive system, reducing energy consumption by 40%, and increasing accuracy to ±0.02 mm, laying the foundation for global robot motion control standards. The rise of the yellow empire (1980s) In 1982, FANUC changed the robot's paint to the iconic bright yellow, symbolizing efficiency and reliability. In the same year, the α series servo motor was launched, with a 50% reduction in size and a 30% increase in torque density, becoming the "heart" of 90% of industrial robots in the world. Industry comparison: During the same period, the average trouble-free time of European robots was 12,000 hours, while FANUC robots reached 80,000 hours (equivalent to 9 years of continuous work), with a failure rate of only 0.008 times/year. II. The global product matrix: How the four trump cards dominate the industry 1. M series: the steel giant arm of heavy industry M-2000iA/2300: The world's strongest load-bearing robot, which can accurately grasp 2.3 tons of objects (equivalent to a small truck) and is used for battery pack assembly at Tesla's Berlin factory. M-710iC/50: Automotive welding expert, 6-axis linkage speed is 15% faster than competitors, weld accuracy is 0.05 mm, and Volkswagen production lines use more than 5,000 units. 2. LR Mate series: precision-made "embroidery hands" LR Mate 200iD: The world's lightest 6-axis robot (weight 26kg), repeated positioning accuracy ±0.01 mm, iPhone camera module assembly yield rate of 99.999%. Application case: Foxconn's Shenzhen factory deploys 3,000 LR Mates, each completing 24,000 precision plug-ins per day, reducing labor costs by 70%. 3. CR Series: The Power Revolution of Collaborative Robots CR-35iA: The world's first 35kg large-load collaborative robot, the tactile sensor can sense 0.1 Newton resistance (equivalent to the pressure of a feather), and the emergency braking time is only 0.2 seconds. Scenario breakthrough: Honda factory uses it to transport engine cylinders, workers and robots share 2m² space, and the accident rate is zero. 4. SCARA Series: The Secret of the Speed ​​King SR-12iA: A planar joint robot that completes the chip pick-and-place cycle in 0.29 seconds, 20 times faster than human operation. The daily output of Intel's chip packaging line exceeds 1 million pieces. III. Global layout: "Unmanned Iron Curtain" from Yamanashi, Japan to Chongqing, China 1. Global factory construction strategy Michigan, USA (1982): Serving General Motors, achieving 95% automation rate of welding lines, reducing the production cost of a single vehicle by $300. Shanghai, China (2002): Production capacity reaches 110,000 units in 2022, accounting for 23% of China's industrial robot market. After BYD's battery production line adopts FANUC robots, the battery cell assembly speed is increased to 0.8 seconds per unit. 2. "Dark Factory" Myth: Robots Make Robots The headquarters factory in Yamanashi, Japan has achieved: 720 hours of unmanned production: 1,000 FANUC robots independently complete the entire process from parts processing to whole machine testing. Zero inventory management: Through real-time scheduling through the FIELD system, the material turnover time is compressed from 7 days to 2 hours. Extreme energy efficiency: Each robot consumes only 32kWh of energy per production, which is 65% lower than traditional factories. Industry comparison: The average output value per capita of similar factories in Germany is €250,000/year, while the average output value per capita of FANUC's dark factory is €4.2 million/year. IV. Intelligent future: 5G+AI reconstructs manufacturing rules 1. FIELD ecosystem: the "super brain" of the industrial Internet of Things Real-time optimization: connecting robots, machine tools, and AGVs, a gearbox factory compressed the tool change time from 43 seconds to 9 seconds through FIELD. Predictive maintenance: AI analyzes 100,000 sets of motor vibration data, with a fault warning accuracy of 99.3%, reducing downtime losses by $1.8 million/year. 2. 5G+machine vision revolution Defect detection: A robot equipped with a 5G module can identify 0.005mm scratches through a 20-megapixel camera, which is 50 times faster than in the 4G era. AR remote operation and maintenance: Engineers wear HoloLens to guide Brazilian factories in maintenance, and the response time is shortened from 72 hours to 20 minutes. 3. Zero-carbon strategy: the ambition of green robots Energy regeneration technology: The robot recycles electricity when braking, saving 4,000 kWh per unit per year, and Tesla's Shanghai factory saves $520,000 in electricity bills per year. Hydrogen power experiment: The M-1000iA driven by hydrogen fuel cells will be put into trial operation in 2023, with zero carbon emissions. Conclusion: The survival rules behind extreme efficiency FANUC builds a moat with "technological closure" (self-developed servo motors, reducers, and controllers), and uses "unmanned production" to reduce costs to 60% of its competitors. Its global gross profit margin of 53% (far exceeding ABB's 35%) confirms Seiuemon Inaba's famous saying: "Efficiency is the only currency in the industrial world."

Deviations in the position and shape of the workpiece cause the robot's taught welding trajectory to be “corrected”. KUKA's Touch Sensor package corrects these deviations before welding, and when the workpiece deviates from the original path, it is located by means of a wire or other sensors, and the original trajectory is compensated for in the program. I. Detection Principle The KUKA robot with Touch Sensor detects the correct weld position of the workpiece by contacting the workpiece with a welding wire and forming a current loop within a predetermined distance, as shown in the diagram below. KUKA's absolute position encoders memorize the position (x/y/z) and angle (A/B/C) of the welding torch in space in real time. When the robot touches the electrically charged wire to the workpiece according to the set program, a loop is formed between the wire and the workpiece, and the control system compares the current actual position with the position parameters from the teach-in. The new welding trajectory is corrected by combining the current data with the demonstration trajectory, and data correction is performed to correct the welding trajectory. The use of the contact sensor position-finding function can determine the deviation between the actual position of the component or part on the workpiece and the programmed position, and the corresponding welding trajectory can be corrected. The position of the starting point of the weld can be determined by contact sensing at one to three points; the number of points required to correct a deviation in the overall position of the workpiece depends on the shape of the workpiece or the position of the weld seam. This position finding function can be used to correct any number of individual points, a section of the weld program, or the entire weld program, with a measurement accuracy of ≤ ± 0.5 mm, as shown in the figure below. Second, the way to use 1. Software Installation TouchSensor welding position finding software package is usually used in conjunction with other KUKA welding software packages, such as ArcTech Basic, ArcTech Advanced, SeamTech Tracking and so on. Before installing the software package, it is recommended to back up the robot system to prevent system crashes, the need for KUKA robots dedicated system backup restore USB flash drive can be the background reply to the KUKA USB flash drive to get, the installation of the software package refer to the “KUKA Robotics Software Options Packages Installation Methods and Precautions”. 2. Command creation 1) Open the program->Commands->Touchsense->search, insert the search command. 2) Set seek parameter->Teach seek start point and seek direction->Cmd OK to complete the seek command. 3) Commands->Touchsense->correction->Cmd ok, insert offset command 4) Commands->Touchsense->correction off->Cmd ok, insert offset end command 3. Operating steps The calibration of the workpiece must be carried out prior to the execution of automatic positioning. 1) Set up the coordinate system for position finding. 2) Place the workpiece in a suitable position, and do not move the workpiece during the calibration process. 3) Create the position finding program 4) Create the trajectory path program 5) Select the search table to be used, and choose the appropriate search pattern according to the specific needs. Set the search mode to 'master' calibration. For example. 6) Execute the program between SearchSetTab and SearchTouchEnd. 7) Set search mode to 'corr' in search SetTab. For example. 8) The workpiece can now be moved and the correctness of the path verified. For safety reasons, it is best to run in T1 mode. Application examples (1) Simple search Simple search Need to search twice in different directions to find the actual position of the object on a position. The first search only defines the position information in one search direction (e.g. x), the second search defines the position information in other directions (e.g. y), and the starting position of the second search defines the remaining position information (e.g. z, a, b, c). (2)Circle Search Three searches in two different directions are required to determine the center of a circle in space. (3) One-dimensional translation CORR-1D Search (4) Two-dimensional translation CORR-2D Search (5) 3D Panning CORR-3D Search (6) One-dimensional rotation Rot-1D Search (7) Rot-2D Search (8) Rot-3D Search (9) Bevel V-Groove Search Two searches in opposite directions are required to determine the midpoint of the joint between two positions (X, Y, Z, A, B, C). (10) Single Plane Plane Search (11) Intersection Plane Search      

In the industrial manufacturing of this vast and sprawling “lake”, welding technology is to hold up a piece of heaven, known as many products from “parts blank” to “perfect finished product” the key to the “Bridge”. Among them, spot welding is by virtue of the unique “charm”, in all kinds of welding methods to stand firm, become the automobile manufacturing, electronic equipment production, aerospace and many other industries, “guest of honor”.   Imagine how the body of the car from a pile of fragmented sheet metal, into a solid and beautiful whole? Electronic equipment in those precision parts, and how closely connected to ensure stable signal transmission? The answer lies in spot welding. Spot welding, like a highly skilled “invisible tailor”, no needles and threads, but with the help of a strong current and pressure, so that two or more pieces of metal in an instant “into one”, connecting seamless, for the stable operation of the entire industrial production provides a solid guarantee! , its importance is self-evident.   Manual spot welding: the persistence of traditional craftsmen     (A) Operation Scene and Process Walking into the production workshop of the factory, the artificial spot welding work area is full of sparks and the sound of metal collision. Master workers wearing protective masks, wearing heavy overalls, holding welding torches, staring intently at the workpiece in front of them. Artificial spot welding operation steps rigorous and meticulous. First, the workers need to precisely position and fix the metal sheets to be welded on the working table to ensure that their positions are exactly the same. This step is like laying the foundation when building a house. If the foundation is firmly laid, the subsequent work can be carried out smoothly. Next, the worker grips the torch and adjusts the current and pressure parameters. The setting of these parameters is critical, just like the chef frying on the fire and seasoning grasp, directly affecting the quality of welding. After all the preparations, the worker pressed the welding torch switch, the strong current instantly through the electrode, so that the contact point of the metal plate quickly warmed up to reach the melting point after the fusion of each other. In a few seconds, a welded joint is formed. The master workers operate in this way, one welding point after another, and with skillful techniques and rich experience, the fragmented metal sheets are gradually spliced into complete products.   (B) Unique Advantages The biggest advantage of manual spot welding is its unparalleled flexibility. When facing workpieces with complex shapes and special structures, robots may be helpless because of the limitations of programs and mechanical structures, but manual spot welding workers can cope with it easily. They can adjust the angle, strength and welding time of the welding torch at any time according to the actual situation, ensuring that every welded joint is perfect. The advantages of manual spot welding are especially obvious in the production of some small processing plants or customized products. For example, some hand-made high-end auto parts, according to the customer's special needs for personalized design and manufacturing. At this time, manual spot welding workers can rely on their own experience and skills, in the complex shape of the precise welding, to meet the customer's requirements for the uniqueness of the product. For example, in the production of metal frames for some artistic sculptures, irregular shapes and special welding requirements make it possible to realize the perfect presentation of creativity only with manual spot welding.   (C) Challenges However, artificial spot welding is not perfect, it is facing a number of serious challenges. From the efficiency point of view, manual spot welding is relatively slow. The number of welded joints that a skilled worker can complete in a day is limited. In today's mass production, this efficiency is difficult to meet the growing market demand. Compared with robotic spot welding, the speed gap between manual spot welding is even more obvious, which to a certain extent limits the capacity expansion of enterprises. Quality stability is also a pain point of manual spot welding. The human state can be affected by a variety of factors, such as fatigue, emotions, fluctuations in skill level, etc.. Even experienced workers find it difficult to ensure that the quality of each solder joint is exactly the same. This may lead to uneven product quality, increase the rate of defective products, and bring economic losses to the enterprise. In addition, the working environment of manual spot welding is also hazardous to workers' health. The spot welding process generates a lot of glare, high temperature, smoke and harmful gases. Long-term exposure to such an environment makes workers susceptible to eye diseases, respiratory diseases, etc., causing irreversible damage to their bodies.   Robotic spot welding: the rise of the tech nouveau riche     (A) cool debut In today's rapid development of science and technology, robot spot welding, as a “technological nouveau riche” in the field of welding, is emerging in industrial production with its unique charm and powerful strength. Into the modern factory, you will see a unique shape, smooth lines of the robot spot welding equipment neatly arranged in the production line. They are like steel warriors from the future, exuding a strong sense of technology. Robot spot welding equipment mainly consists of robot body, control system, spot welding system, sensors and other components. The robot body usually adopts multi-joint design, with high flexibility and range of motion, and can easily reach a variety of complex welding position. The movements of its robotic arm are precise and smooth, as if it were a rigorously trained dancer, and every movement is just right. The control system is the “brain” of the robot spot welding equipment, which is responsible for directing the robot's every move. Through advanced programming technology and intelligent algorithms, the control system can accurately control the robot's movement trajectory, welding parameters, etc., to ensure that the welding process is efficient and stable. Spot welding welding system, on the other hand, is the “weapon” of the robot spot welding equipment, which consists of welding controller, welding tongs and auxiliary parts such as water, electricity and gas. The welding controller can accurately control the welding current, voltage and time, so that the quality of the welded joint is reliably guaranteed. The design of the welding clamp is also very delicate, it can flexibly adjust the clamping force and welding angle according to different welding needs to ensure the accuracy and firmness of welding. Sensors are like the “eyes” and “ears” of the robot, which can sense various information in the welding process in real time, such as the position of the weld seam, the size of the welding current, the change of temperature, etc., and feedback this information to the control system in order to timely adjust the welding parameters to ensure welding quality.   (B) the secret of high efficiency Robot spot welding can be rapidly popularized in industrial production, the key is that it has many compelling advantages, especially in terms of speed, precision and consistency, but also excellent performance. In terms of speed, robot spot welding is called “fast”. It can complete a large number of spot welding tasks in a short period of time, and its efficiency far exceeds that of manual spot welding. Take the automobile manufacturing industry as an example, an ordinary car body needs to weld thousands of welding points, if the use of manual spot welding, need to spend a lot of time and manpower. And the use of robot spot welding, only a few hours to complete all the welding work, greatly reducing the production cycle, improve the productivity of enterprises. Precision, robot spot welding is the ultimate. It can accurately control the welding position and welding parameters, the error can be controlled within a very small range. This is crucial for some products that require very high precision. In the manufacture of electronic equipment, the welding accuracy of components directly affects the performance and quality of the product. Robotic spot welding can ensure that each weld joint is in a precise position, and the welding quality is uniform and consistent, thus improving the yield rate of the product and reducing the defective rate. Consistency is also a highlight of robotic spot welding. Because the robot works according to a preset program and is not affected by fatigue, emotions and other factors, it is able to ensure that the quality of each welded joint is stable and reliable. Whether in a long period of continuous work, or in the mass production process, the robot spot welding can consistently maintain a high level of quality welding, to provide enterprises with stable product quality assurance. In the automobile manufacturing industry, the application of robot spot welding has been very extensive. Major automobile manufacturers have adopted robot spot welding technology to improve production efficiency and product quality. For example, Tesla's automobile production line, a large number of robot spot welding equipment, these robots can quickly and accurately complete the welding of various parts of the body, making Tesla's production efficiency and quality have been greatly improved. At the same time, the robot spot welding can also realize flexible production, quickly adjusting welding procedures and parameters according to the needs of different models, providing a possibility for personalized customization of automobile production.   (C) The truth about costs The initial investment cost of robotic spot welding is indeed relatively high. Purchase a robot spot welding equipment, less than tens of thousands of dollars, more than a hundred thousand or even more, which does not include the installation of equipment, debugging and later maintenance costs. In addition, in order to allow the robot to work properly, enterprises also need to invest a certain amount of money for plant renovation, personnel training and so on. For some small enterprises, such initial investment may bring greater financial pressure. However, if we look at the long term, the cost advantages of robot spot welding will gradually emerge. First of all, the robot's service life is longer, generally up to several decades. During this period, the robot can work 24 hours a day, creating continuous value for the enterprise. Manual spot welding needs to take into account factors such as rest and vacation of workers, the actual working time is relatively short. Secondly, robotic spot welding is highly productive and can accomplish more work in the same amount of time. This means that enterprises can produce more products in a shorter period of time, thus increasing their income. Furthermore, robotic spot welding can effectively reduce the rate of defective products and improve product quality. This not only reduces the loss of enterprises due to defective products, but also improves the brand image of enterprises and increases market competitiveness. Finally, with the continuous progress of science and technology and the development of the robot industry, the price of robotic spot welding equipment is also gradually reduced, maintenance costs are also decreasing, which further enhances the cost advantages of robotic spot welding.     In order to more intuitively show the difference between manual spot welding and robotic spot welding, we compare and analyze the five dimensions of efficiency, quality, cost, safety, and flexibility, which are presented in table form as follows:     Comparison Dimension Manual spot welding Robotic spot welding Efficiency Restricted by workers' proficiency and physical strength, relatively slow speed, limited working hours, difficult to work for a long time with high intensity, low efficiency in mass production. Fast speed, 24 hours non-stop work, stable work efficiency, can complete a large number of welding tasks in a short period of time, greatly shortening the production cycle Quality Easily affected by the state of workers, emotions, technical level fluctuations and other factors, quality stability is poor, different workers or the same worker at different times welding quality varies, the defective rate is relatively high. Through precise programming and control system, precise control of welding parameters, stable welding quality, high consistency, can effectively reduce welding defects and scrap rate, to meet the requirements of higher quality. Costs Low cost of equipment, mainly the cost of basic welding torch and simple jigs and fixtures, but need to pay for labor costs such as wages, benefits, social security, etc., and in the long run, the labor cost grows with time. Initial equipment procurement, installation and commissioning, plant renovation, personnel training costs are high, the later maintenance costs are relatively fixed, the robot has a long service life, long-term operation, due to high efficiency, low defective rate, the overall cost has advantages Safety The working environment is characterized by glare, high temperature, smoke, harmful gases and other hazards, workers are susceptible to eye and respiratory diseases, and there are safety hazards such as metal spatter and electric shock during operation. Operators are not directly involved in the welding process, can be away from the harsh working environment, reduce the safety risk, to protect the health and safety of workers. Flexibility According to the actual situation at any time to flexibly adjust the welding torch angle, strength, welding time and other parameters and processes, to adapt to the complex shape, special structure of the workpiece as well as small batch, personalized custom production. Complex settings and adjustments need to be made through the programming and control system, the operation is relatively cumbersome and not flexible enough to deal with complex and non-standard tasks, and it is more suitable for large-volume, highly repetitive welding tasks.     Looking to the future, the welding industry on the stage, manual spot welding and robot spot welding is not “your side sings I debut” alternative relationship, but hand in hand with the “best partner”.   In the “battlefield” of large-scale standardized production, robotic spot welding will continue to play its efficient and accurate advantages, and become the “main force” on the production line. They work tirelessly, with stable quality and ultra-fast speed, for enterprises to continuously output high-quality products to meet the market demand for large-scale products. For example, in the large-scale production line of automobile manufacturing, robot spot welding can quickly complete the welding of the body to ensure that the quality of each car has reached a uniform high standard.   And artificial spot welding will not be retired, in those who need “craftsmanship” niche areas and personalized custom “creative world”, artificial spot welding is still irreplaceable “protagonist “. It injects a unique soul into the product by virtue of its ability to adapt flexibly and its extreme control of details. When customers need a one-of-a-kind metal artwork, manual spot welding workers are able to manually weld according to the customer's creativity and requirements, giving the work a unique artistic appeal.   In the future, as technology continues to advance, the collaboration between manual spot welding and robotic spot welding will become even closer and more efficient. Robotic spot welding can perform most of the repetitive and high-intensity work, relieving the burden for manual spot welding; while manual spot welding focuses on tasks that require a high degree of skill and creativity, complementing and optimizing robotic spot welding. At the same time, we are looking forward to the emergence of more innovative technologies that can further improve the quality and efficiency of spot welding and bring new breakthroughs to the development of industrial manufacturing.  

Welding Robots: Technological Breakthroughs Drive Market Growth, Enormous Potential Ahead Welding robots are becoming a focal point for capital markets, as rapid technological advancements—particularly in artificial intelligence (AI) and sensor technologies—have laid a solid foundation for their application. Although market penetration is still far from saturation, especially in the steel structure industry, where intelligent transformation remains a challenge, the future demand for welding robots is expected to surge with the widespread adoption of teachless intelligent welding robots. The accumulation of expertise in intelligent systems and integration will be key for companies to stand out in this "blue ocean" market. The welding robot industry has immense application potential not only in traditional steel structure and automotive manufacturing but will also bring profound changes to industries such as metalworking and heavy machinery. For companies with a technological edge, the future promises substantial market rewards. In recent years, the robotics industry has emerged as a hot sector in capital markets, attracting the attention of investors. The underlying reason for this surge lies in the rapid technological advancements, especially the breakthroughs in AI, which have endowed robots with unprecedented intelligence. Additionally, sensor technologies—particularly the progress in miniaturization—have provided a strong foundation for the widespread application of robotics. Among the various fields of robotics, welding robots are increasingly becoming the focal point. Simply put, a welding robot is a highly automated device that integrates robotics technology, artificial intelligence, machine vision, automation control, and software design. Currently, this remains a "blue ocean" market, attracting numerous enterprises vying for a share. For instance, Maggmet has launched its intelligent digital welding machine, which has become a key component of industrial welding robot systems, while Estun has introduced a teachless intelligent welding system based on visual recognition. However, despite the promising market outlook, is the welding robot industry truly as promising as investors expect? Will this market eventually turn into a competitive "red ocean"? Let's analyze it from several perspectives. 1. Breaking the 50,000-unit Barrier: The Potential of the Welding Robot Market The core function of welding robots is, of course, welding, and the primary demand for welding comes from the steel structure industry. According to statistics, China’s annual steel welding volume is approximately 300 million tons, accounting for over 50% of the global total. The shortage of welders also creates demand for welding robots. It is estimated that by next year, China will face a shortage of about 400,000 skilled welders, and the high labor costs are accelerating the adoption of automated welding equipment. In recent years, the sales of welding robots have been increasing annually, with a compound annual growth rate (CAGR) exceeding 10% over the past five years. The sales have already surpassed 50,000 units, with arc welding robots taking the largest market share at approximately 62%. Currently, the automotive industry, particularly standardized and mass production in car manufacturing, has become the largest downstream market for welding robots, with penetration nearing saturation. Although the welding demand in the steel structure industry is substantial, the customization of products in this field means that welding robots have not yet fully achieved intelligent transformation, resulting in relatively low penetration. However, with the gradual promotion of teachless intelligent welding robots, the demand for welding robots in the steel structure industry is expected to reach 500,000 units by 2035, with a market space exceeding 50 billion RMB. 2. Intelligence: The Future Development of Welding Robots In the future, the large-scale application of welding robots, especially in non-standardized fields, will be heavily reliant on intelligence. Currently, the robot body and vision tracking system are the most costly components. The companies that possess full-stack capabilities in hardware and software development, as well as system integration, will have a competitive edge. For example, a robot may scan and identify parts to be welded, optimize the welding path using algorithms, and finally complete the welding task autonomously. Achieving this requires the establishment of a powerful workpiece recognition model and a comprehensive process database to achieve dynamic parametric control of the welding process. To accomplish this, technological innovation and coordinated efforts across various stages will be essential. 3. Technological Breakthroughs: The Core Competitiveness of Intelligent Welding With ongoing technological advancements, traditional industries such as metalworking and heavy machinery are gradually entering the intelligent welding market. The future of welding robots depends on breakthroughs in sensor technology, control systems, and software innovations. In particular, the development of welding models and the application of 3D vision technology will become the core barriers to industry development. The companies that gain a head start in these critical areas will have the opportunity to lead the industry and dominate the market.