Transformation from manual arc welding to collaborative robot welding: Comparison of ergonomic and process-related influencing factors and effects

Abstract

The increasing use of collaborative robots (cobots) in welding for small-batch production is changing both technical processes and the requirements for employees. This paper examines the transition from manual to cobot-based gas metal arc welding (GMAW). The focus is on ergonomic aspects and their evaluation, changes in job profiles, including the required qualification level, as well as process-related aspects such as processing time, post-processing effort, weld seam quality, and shift output.For the ergonomic analysis, a marker-based virtual reality (VR) system is used to record the work process in both scenarios, manual welding and cobot-based welding, and to evaluate it using a scientifically established ergonomic assessment method. Differences in physical strain (posture) and movement profiles between the two welding methods are discussed in order to highlight the potential effects on the health and performance of employees. In addition, the impact of the introduction of cobots on qualification requirements is investigated, as well as the new skills required for planning, programming, and interaction in automated processes. Finally, process-related key indicators are compared to identify possible changes in effectiveness and quality. The discussion addresses the question of the extent to which collaborative robotics can contribute to reducing manual strain while at the same time posing new challenges for work design, work organization, and qualification. The aim is to gain practical insights for the design of future workplaces in the welding sector and to highlight the importance of integrated socio-technical approaches that equally take technology, ergonomics, and qualification into account.

Keywords: Human-centred Work Design, Automated Welding, Cobot-based Welding, Ergonomics In Welding, Qualitfication Requirements, Competence Development, Human-robot Interaction, Human-technology Interaction

DOI: 10.54941/ahfe1007779