The integration of Element X into robotic hardfacing workflows is transforming wear-resistant coating applications from a programming-heavy burden into a high-speed automated process. By reducing programming time from an average of 15 minutes to just under 3 minutes, this technology offers a flexible solution that eliminates the need for brand-specific robot training.
Robotic Hardfacing Time Study
Robotic hardfacing is the process of applying wear-resistant coatings to ground-engaging equipment parts to extend their lifespan. While industrial robots increase precision, their benefits are often undermined by rigid programming requirements.
Our team at Elementiam created Element X robotic hardfacing solutions to solve the issues around time-consuming programming times when using traditional industrial robots, such as:
- Yaskawa Motoman
- Kuka
- ABB
- Fanuc
- And so on…
To validate our solution, we worked with an Alberta fabrication company that discovered time inefficiencies with their robotic hardfacing processes.
We conducted a simple time study to measure how long it takes Element X to create robot programs for different ground-engaging equipment parts and overlay coverage levels. The table below summarizes the time (in seconds) to compute paths and programs for three distinct parts commonly used in heavy equipment:
Part | 10% Coverage | 50% Coverage | 100% Coverage |
Bucket Tooth (Scan + CAD) | 109 seconds | 126 seconds | 142 seconds |
Serrated Grader Blade (Direct Scan) | - | 37 seconds | 75 seconds |
Excavator Lip Shroud (Direct Scan) | - | 35 seconds | 46 seconds |
The average times varied from 35 to 142 seconds, showcasing a significant reduction in overlay path generation times, including alignment, area selection, and path computation. This speed demonstrates the flexibility of Element X's system, which can handle both CAD reference models combined with scans, and direct scanning data for parts like serrated grader blades or excavator lip shrouds. By cutting programming time from hours to minutes, the system removes a major barrier to efficient automation.
Unmatched Flexibility for Varied Workpieces
One of the primary strengths of this industrial robot application is its inherent flexibility. Unlike rigid systems that require a perfect CAD library, Element X can handle diverse part geometries through two distinct workflows:
- CAD & Scan: Ideal for higher volume production parts, like bucket teeth, where existing data can be refined by a quick scan to identify variations. Element X adjusts the robotic hardfacing parameters, deposition, and speed to get the perfect weldment.
- Direct Scanning: Perfect for worn or unique components that are custom, demanding that the system autonomously generate optimal paths without any prior CAD data.
Element X eliminates manual robot programming by integrating advanced 3D scanning vision and adaptive software powered by artificial intelligence. The system instantly maps the exact geometry of a component and autonomously generates the optimal path for the robot.
The Impact of Smart Automation on Canadian Fabricators
For Canadian fabricators, the skilled labor crisis is a daily reality. In order to stay ahead, many shops turn to automated systems, but therein lies a common problem: Traditional automation often requires costly, brand-specific training for operators. This creates a significant business risk when companies invest heavily in certifying a technician, only to see that ROI vanish if the employee leaves the company.
Element X removes this barrier by making the robot accessible to entry-level operators. In 2-3 days of training, operators can execute robotic hardfacing using our user-friendly program to carry out custom fabrication for a wide breadth of complex part geometries. This helps fabricators maximize their efficiency through time savings and precision.
Eliminate Brand-Specific Training on Robots
No more time-consuming, expensive manufacturer-specific training courses.
Accessible Operation for Hardfacing and Other Weld Procedures
Allows experienced tradespeople to focus on quality control while the system handles the complex path-finding calculations.
Future-Proof your production line
By lowering the barrier to entry for automation, Canadian manufacturers can scale their throughput and remain competitive despite local labor market fluctuations. Element X doubles the production throughput by minimizing robotic programming times and putting automation into the hands of tradespeople.
discover adaptive, smart automation solutions
The Elementiam team delivers customized solutions to enable Canadian fabricators to adopt automation that is flexible enough to take on custom fabrication.
Talk to a member of our team to learn more: Book a discovery call today!