An analysis of the efficiency and accuracy of manual and autonomous four-wheeled linear welding across various parameters

This study investigates the performance of manual versus autonomous welding performance using a four-wheeled linear welding robot, focusing on stitch and continuous welding methods for dissimilar materials. To better understand how welding speed influences weld quality across different dissimilar material thicknesses, the research compares the effectiveness of manual and automated welding procedures. The findings indicate that both welding speed and material thickness significantly impact the performance of manual and autonomous welding processes. While manual welding demonstrated greater adaptability and flexibility for handling complex geometries and non-standard welding applications, autonomous welding offers higher accuracy and repeatability in standard welding techniques. This study provides valuable insights into the relative effectiveness of manual and automated welding methods in linear welding contexts. By carefully selecting and optimizing welding parameters for each welding technology, manufacturers can enhance weld quality, minimize defects, and achieve more precise and efficient welding operations. The results demonstrated that using a four-wheeled linear welding robot instead of manual welding saves welding time by approximately 40%. It could positively affect the company’s profitability, efficiency, and cost savings. The present work focuses on designing and developing a four-wheeled linear welding robot to perform high-quality linear welds. In addition, this study compares manual and automated welding techniques using specific measurements. Weld quality was assessed for manual and automated welding using penetration depth, weld strength measurements, and distortion evaluation.