Multi-Process Welding - Midwest Engineered Systems

MWES custom automation systems combined with multi-process welding power supplies allow the mixture of ferrous and non-ferrous joining applications using the same equipment with automated change-over from one process to another. Multi-process automated welding systems maximizes speed, output and accuracy, particularly for challenging welds. MWES can integrate a variety of multi-process welding setups including:  

Non-Multi-Process Weld Systems

Automated arc weld systems are split up into different process capabilities for different applications. These integrated weld systems are gas tungsten arc weld (TIG), gas metal arc weld (MIG/MAG) and shielded metal arc weld (MMA) process. Many robotic weld systems are designed to carry out more than one process with regard to TIG, MIG/MAG or MMA, but meeting this condition doesn’t necessarily make those automated systems multi-process ones.

A MIG/MAG weld system may have the technical and manufacturing capabilities to incorporate MMA processes; MMA processes may also be integrated with current TIG technical capabilities. While these combinations are possible and have their advantages (such as reduced workload), this tends to cause reductions in total output, arc stability, or other problems for at least one of the processes. In the end, these systems do not possess real multi-process capability. True multi-process systems are ones that can execute all TIG, MIG/MAG and MMA processes with virtually no loss in performance standards between them.

Standard vs. Multi-Process Systems

With standard integrated weld systems, the welding automation machinery is designed to specialize in just one of the processes (TIG, MIG/MAG, MMA). They tend to have certain features and functions that allow them to perform their particular process with great efficiency and user-friendliness. High-frequency ignition is a staple of today’s TIG weld systems. MIG/MAG weld systems operate using multiple different settings, allowing for a wide range of adaptability in terms of weld arcs and weld seam dimensions. MMA weld systems optimize high arc stability and its ignition characteristics.

By contrast, a robotic multi-process system’s focus is on flexibility. The idea is that no matter what needs to be weld and no matter what automated process(es) need to be used, a multi-process system is well-equipped to handle the job. Multi-process tools are very adaptable and some in small sizes, making the overall systems much more portable than standard process ones. One necessary consequence of all of this flexibility is that compromises have to be accepted for certain features. For instance, an additional feature such as a high-frequency ignition ultimately increases the weight of the weld device and therefore lowers its overall portability.

Effective Multi-Process Systems

Generally, effective multi-process systems should meet all of the following conditions:

• TIG mode with a second gas solenoid valve
• A single control panel containing all three processes
• TIG Multi Connector (TMC) for use with a TIG U/D torch
• Ability to regulate between TIG, MIG/MAG and MMA processes

Benefits of Multi-Process Welding 

• Flexibility among processes
• Decreased Training Demands
• Higher Adaptability to welding tasks
• Reduced Investment Costs

While this is only a small portion of our welding integration capabilities, we can design any system to meet your needs from automating manual processes or upgrading current robotic systems. Contact Us to learn more!