nexAir’s Contribution to the Welding Industry: Embracing Robotics for Enhanced Performance

Precision robots demand precision support. When a shop installs its first automated welding system, everything changes – including gas delivery requirements that many never considered.

The Hidden Demands of Robotic Welding

Picture this scenario: A top-of-the-line welding robot sits idle while technicians troubleshoot inconsistent welds. The machine settings look perfect. The programming is flawless. Yet something’s off.

Often, the culprit lurks in the gas system. Robotic welders create unique demands:

“The machine never gets tired, never varies its torch angle, and never changes its travel speed – but it absolutely requires consistent inputs to deliver consistent outputs,” explains one automation specialist with decades of experience.

Those inputs include uninterrupted gas flow that maintains identical pressure from the first weld to the last, even across 24-hour production cycles. Traditional gas setups rarely deliver this level of stability.

Breaking the Bottleneck

nexAir approaches automation support differently. Rather than focusing solely on the robot, we examine the entire system that feeds it.

Pressure mapping often reveals surprising issues. Gas flow might drop during peak production hours when multiple stations draw simultaneously. Delivery lines could create unnecessary resistance. Even regulator response times can introduce subtle variations that robotic welders magnify into visible problems.

Solutions range from surprisingly simple to strategically complex:

• Dedicated supply lines that bypass shared manifolds
• High-response regulators that maintain set points under fluctuating demand
• Microbulk installations that eliminate pressure drops during cylinder changeovers

For one manufacturer running three shifts, switching from cylinders to a centralized system eliminated the twice-daily quality variations that coincided with gas changeovers – a correlation they hadn’t even recognized.

Operators: The Human Element in Automated Systems

Contrary to popular belief, automation increases the value of skilled personnel. It simply shifts their focus from torch manipulation to process oversight.

“I used to be the one laying the bead,” says one veteran welder now managing a robotic cell. “Now I’m the quality control, troubleshooter and improvement specialist rolled into one.”

nexAir develops training specifically for this transition. Sessions focus on:

• Visual identification of gas-related issues in robotic welds
• Rapid diagnosis of flow problems before they create scrap
• System monitoring techniques that prevent production interruptions

This investment in human capability pays dividends when operators catch subtle changes before they become production problems. The combination of automated precision and experienced oversight creates results neither could achieve alone.

Creating Systematic Success

The distinction between good and exceptional automated welding often lies not in the robot itself, but in the ecosystem supporting it. When every component – from gas delivery to operator knowledge – works in harmony, the results speak for themselves.

“The same robot with the same program can produce wildly different results depending on its support systems,” notes one production engineer. “We’ve seen this firsthand.”

nexAir helps manufacturers Forge Forward by ensuring that automated welding systems receive the consistent inputs they require to deliver their promised precision. The approach focuses on practical outcomes: reduced variation, increased uptime, and quality that meets the most demanding specifications.

Contact us to learn more about optimizing your gas systems for robotic welding success.