{"id":6055,"date":"2025-03-10T05:30:27","date_gmt":"2025-03-10T05:30:27","guid":{"rendered":"urn:uuid:8784b7b7-514d-4d29-8320-94740d158d92"},"modified":"2025-08-25T04:22:27","modified_gmt":"2025-08-25T04:22:27","slug":"flexible-and-consistent-robotic-arc-welding","status":"publish","type":"case_study","link":"https:\/\/kawasakirobotics.com\/eu-africa\/case-studies\/flexible-and-consistent-robotic-arc-welding\/","title":{"rendered":"Flexible and Consistent Robotic Arc Welding"},"content":{"rendered":"\n
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Download PDF<\/a><\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

OVERVIEW<\/h2>\n\n\n\n

As experienced arc welders grow scarce and mass production amplifies the need for consistency, many companies are at a loss. They need to weld their parts, but it\u2019s difficult to find skilled welders who can produce high quality products – let alone maintain that standard hourly. Today, advances in robotic arc welding<\/a> make it possible for companies to experience the quality and consistency of an expert arc welder on their best day, every single weld.<\/p>\n\n\n\n

In the mid-1980s, Kawasaki Motors Manufacturing Corp., USA (KMM) installed their first Kawasaki robots to weld their all-terrain vehicle (ATV) and Mule and Teryx four-wheeler frames. Thirty years later, the manufacturer uses 71 Kawasaki arc welding robots, and that number will grow to 84 by June of 2019.<\/p>\n\n\n\n

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\"The
The inside of a Type 3 cell, which uses a Kawasaki RS010L robot to weld long parts.<\/figcaption><\/figure>\n\n\n\n

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CHALLENGES<\/h2>\n\n\n\n

KMM didn’t need automation to increase their production volume. However, they needed robotic arc welding to maintain their current rate of production while providing a more repeatable frame. They also needed a versatile solution that could weld a variety of parts.<\/p>\n\n\n\n

A solution for labor shortages<\/strong><\/h5>\n\n\n\n

For years, KMM fought an uphill battle against labor shortages in the welding industry. Now, 80% of KMM\u2019s arc welding processes are automated using Kawasaki robots, and only 20% of the work needs to be done manually. Now, trained welders can do the additional work, which includes double checking the robot’s work or accessing hard-to-reach areas.<\/p>\n\n\n\n

Consistency and reliability<\/strong><\/h5>\n\n\n\n

Product quality standards are always increasing, and meeting them with manual methods is a challenge. KMM does mostly pipe-to-pipe welding, so they need highly repeatable robots to run programs without having to see the path. To meet this need, Kawasaki RS010L robots have a repeatability of \u00b10.05 mm, which results in a highly consistent product. \u201cKawasaki robots are by far the most reliable that we\u2019ve seen on the market,\u201d Gordon said.<\/p>\n\n\n\n

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\"KMM's
KMM uses the Battle Bot cell to weld full ATV and four-wheeler bodies.<\/figcaption><\/figure>\n<\/div>\n\n\n\n
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\"The
KMM uses the Kneeling Easel cell to weld large, cumbersome cab frames.<\/figcaption><\/figure>\n<\/div>\n<\/div>\n\n\n\n

SOLUTION<\/h2>\n\n\n\n