Mechanisation of welding processes
Mechanising welding processes is a step towards higher productivity. We supply, design and manufacture mechanical equipment (columns, rotators, positioners, carriages) that takes over the heavy physical work and keeps welding operations stable. This raises efficiency and prepares the production for further automation, should it be needed.
What mechanisation of welding is
The terms mechanisation and automation are often confused, but they are different engineering tasks.
Mechanisation is the introduction of mechanical devices and units that replace or simplify manual work without complex control systems: drives, gearboxes, guides, tooling and manipulators operated by a person. Mechanisation leaves process control with the operator.
Automation adds a programmable control system, and the equipment performs welding, cladding or another operation to a set algorithm without human involvement.
It is important to understand that mechanisation is not a cheap version of robotization. It is an engineering tool for raising efficiency in its own right.
But if your business grows and mechanical solutions are no longer enough, mechanisation can become the first stage of a wider project: production automation. The equipment we design today can be upgraded tomorrow into a fully automatic system.
What mechanisation solves
Higher throughput of the welding station. Time spent setting up and positioning the part and moving the welder is cut. Output grows without additional staff.
Less dependence on manual labour and the human factor. The quality of manual welding depends directly on the welder's experience and condition. Mechanisation removes these factors, raising quality and lowering the scrap rate.
More stable welding operations. Fixing the part or guiding the weld along rails rules out vibration and jerks. This is critical when welding critical structures and alloy steels, where the cleanliness and geometry of the seam matter.
Fewer injuries and better working conditions. Giving up manual turning of heavy blanks and similar operations directly lowers industrial injuries and protects employees' health.
Preparation for automation. Mechanisation is the foundation for future development. Once the process runs on mechanical equipment, you understand the bottlenecks and can move on to automation painlessly.
Solutions we deliver
Our specialists design and integrate equipment for the customer's specific process:
- Welding columns and booms;
- Positioners and manipulators;
- Welding carriages and gantries;
- In-shop transport and conveyor systems: roller tables, trolleys and transfer devices for moving large welded assemblies between stations.
When mechanisation beats robotization
In the pursuit of technology many plants make the mistake of introducing robots where a simple mechanical solution would do. We take a rational approach.
Economic efficiency. Mechanical equipment costs several times less than a robotic system. For medium-batch production with simple weld joints, mechanisation pays back much faster.
Mechanisation is the logical first step. If production volumes are unstable and the product range changes, start with mechanisation. It raises efficiency and gathers the data needed to judge whether future robotization makes sense.
How we implement mechanisation: project stages
We mechanise plants on a turnkey basis, from development to commissioning and service. The workflow is built to exclude risk for the customer.
- We receive your request. You describe the task: welding type, part dimensions, the desired result.
We audit the production. Our engineers visit the site (or hold an online meeting) to study the process, take measurements and consult your technologists.
We develop the project and prepare a proposal. We design the schematic, select the units, develop the tooling and send you a technical and commercial proposal.
We agree the technical solution. Details are clarified, corrections made and the final concept approved.
Procurement and assembly. We order the main units, additional equipment and components, develop and manufacture the tooling, and assemble and test the system at our plant.
Delivery, installation and commissioning.
Start of operation.
Service support. We stay in touch, advise, help adjust to a new product range and provide service when needed.
The result for the plant
After mechanical welding systems are introduced, production moves to a new technological level:
- Higher labour productivity;
- Better product quality;
- Better working conditions and less strain on production staff;
- A foundation for further production automation.
Submit an enquiry and Teswel specialists will assess the mechanisation potential of your welding station and give a free consultation.