The American Welding Society estimates a shortage of 290,000 skilled welding professionals. In addition, the nature of manufacturing in the U.S. shifted to JIT (just in time) beginning in the 1980s. Manufacturers produce a number of products, with high quality in a short amount of time.
Welding robots step into the labor shortage at an advantage. They can work tirelessly, they need training once for a product and their work is consistent. The OTC welding robot improves performance and productivity.
Robot welders can work with hazardous materials or dangerous conditions without injury.
Read on to learn more.
The first industrial robot was patented in 1961. Called the Unimate, was used for transporting die castings and spot welding in a General Motors automobile factory. Instead of human workers risking a toxic and dangerous work situation, this 2,700-pound robotic performed the assembly.
The original industrial robot used hydraulic actuators. It was programmed with joint coordinates in a teaching phase, then would replay those coordinates faithfully.
Rapid industrial adoption of robots to perform hazardous work meant that the manufacture and distribution of robots were widespread by the 80s. Robots could carry out specific actions over and over again. Repetitions are highly accurate and do not vary.
Program routines specify the direction, time, speed, and distance of a series of coordinated motions. Robotic controls evolved from vacuum tubes to transistors, then on to computerized control.
OTC stands for the Osaka Transformer Company, founded in 1919. In the late 1970’s, OTC Daihen developed its first dedicated arc welding robots. In 1983, THOR, the OTC welding robot entered the U.S. market. OTC Daihen USA operates its headquarters in Dayton, OH and has branch offices in Charlotte, NC Atlanta, GA; Novi, MI; and Monterrey, Mexico.
Like all OTC Daihen welders, it’s a pioneer in advanced features like
It is a 7-axis robot with a 6-kg payload and 1.4 m reach. Nothing equals it for small-run fabrication for accuracy and precision welds. Rotation of the 7th-axis does not change the position and/or attitude of the tool.
It maintains the optimal angle and attitude of the tool for high weld quality and easy programming. The independently articulated arm has a wide range. It has a digital connection with its power supply.
For accuracy, it has superior vibration restraining control for smooth robot movement. It has a built-in shock sensor. Its memory capacity supports most welding applications.
Robot controls use Windows XP open architecture. It can connect to Ethernet, DeviceNet or PROFIBUS connections.
The teach pendant is efficient. Advanced PLC functions allow for ladder diagram edits. The icon displays permit easy and fast teaching. The standard touch screen display and jog dial operation mean that teaching the process requires only minor refinements before production.
The OTC welding robot easily bends around corners, avoids interference and adjusts perfect torch position and attitude. It can get a consistent weld of much higher quality than even an experienced welder.
A 7-axis robot doesn’t require repositioning to work around a piece. Movement can cause a loss of quality. It can bend around obstacles, like tooling, the workpiece or other obstructions. No loss of attitude.
The OTC welding robot reduces overhead costs because it requires no extra floor space, positioners or other equipment. The robot can get into small spaces a retooling takes moments, not days.
Quality is the top priority of All Metals. The use of the OTC welding robot meets our ongoing effort to deliver high quality builds promptly.
Our policy of continuous improvement means we are always looking to be more efficient in every aspect of our operation. Our clients are valuable and we want to improve our service.
We practice lean manufacturing principles. We increase quality, lower costs and reduce turn time for our customers. Our implementation of the 5-S process means that we cut waste. This includes wasted time, materials, or idle equipment.
Our quality standards are based on ISO 9001. We build industry-specific tolerances and standards for each customer. Each operation undergoes inspection through every procedure. by set up sheets, 1st Article inspections, source inspections, and final inspections.
We are an ISO 9001:2015 certified company. We use a FaroArm for 3D scanning and an Inspecvision Planar system to allow machine operators to check their parts in the flat. This equipment, and our Brown & Sharpe Xcel Coordinate Measuring Machine, maintains our reputation of high-quality products for our clients and helps us eliminate waste.
Our reputation for quality manufacturing and accurate welds is enhanced by the OTC welding robot. Our average employee tenure is 15 years and we provide the best tools and training for high-quality manufacture.
We service many diverse industries
We have a wide range of manufacturing capabilities. Our knowledge and state-of-the-art equipment enable us to support you. In addition to precision fabrication, we offer silkscreening, powder coating, laser cutting and more.
We can bring you from the initial concept design to proof of concept. Then take you through production, finishing, and assembly.
We are devoted to the very highest quality and consistency. We look forward to the opportunity to meet and exceed your requirements. Contact us today to discuss how we can be your trusted manufacturing partner.