Let’s talk about torch kits. What are the trade-offs for buying tools individually or all at once? Which one best fits your needs? Some of the best selling welding/cutting kits are the Victor Torch Kits.  With a multitude of torch sets and outfits, Victor has the right tools for all different sorts of welding and cutting. 

What You Need To Know About Oxy-Fuel Cutting & Welding

Oxy-fuel technically speaking is a combination of oxygen and any fuel gas (typically propane, propylene, natural gas etc.), but the specific combo to focus on is arguably the most popular: Oxy-Acetylene welding and cutting. To talk about the chemical details of cutting and welding, I’ll use the terms oxy-fuel and oxy-acetylene interchangeably. 

The heat generated from the combustion of oxygen and the hydrocarbon compound acetylene is used to weld materials together, but can also be used as a jet stream to cut materials. The materials mainly used in oxy-fuel welding are steel, brass, and copper. For cutting, mild steel is the main material used. The most common uses for oxy-fuel welding are welding thin metals such as:

• jewelry repair
• electronic repair,  and 
• crafts or hobbies out of a home-based shop.

Oxy-fuel welding and cutting proves to be extremely versatile, with cutting being the more common practice of the two. No matter the size of the project, Victor carries a large variety of torches for all kinds of uses!

Light-Duty Torch Kit

Our most popular light-duty torch is the Victor G150-J-P Portable Tote without tanks.

This kit includes:

• Color coded gas hoses
• Oxygen regulator
• Acetylene regulator
• Striker
• Safety cutting glasses
• Brazing nozzle
• Heating nozzle
• Torch handle with check valves
• Carrying tote
• Couplings
• Tank wrench

A huge selling point for this particular torch kit is the portability. A lot of reviews will show the (separately purchased) gas tanks in the carrier and the hose wrapped around the tote, making the kit something you can take or store virtually anywhere. This set is capable of HVAC and plumbing brazing applications. This comes with a  7 Year Warranty on the Regulator and a 10 Year Warranty on the Torch Handle and Cutting Attachment.

Other Victor light-duty options:

• Victor G150 Portable Tote 0384-0944
• Victor G150 Portable Tote 0384-0947

Other kits may cut thicker plates but struggle to weld. This Victor kit can cut up to ½” plate and weld up to ¼”. With all these features at a budget-conscious price, a light-duty kit makes simple jobs even simpler.

Medium-Duty Torch Kit

Our most popular medium-duty torch kit is the Victor Performer EDGE™ 2.0.

This kit includes: 

• Color coded gas hoses
• Oxygen regulator
• Acetylene regulator
• Striker
• Googles
• Tip cleaner
• Torch tip
• Torch handle with check valves
• Cutting attachment
• Heating nozzle
• Brazing nozzle

One benefit for purchasing the kit over all the individual pieces, is certainly the COST. This Victor torch kit total is $279.89+tax (free S&H over $100). When you add all these items together purchased piece by piece, at the lowest cost your total winds up being roughly $320 before shipping or tax. Someone could argue that you may not use all the pieces in this Victor torch set, however you have them available in case you need them, and at the kit’s price they’re practically free. This torch set can cut up to 6” and weld up to ¼” and comes equipped with everything you would need to get started, aside from a fuel source.

Other Victor medium-duty options:

• Victor Medalist®250 CLASSIC Medium Duty Cutting and Welding Outfit 0384-2581
• Victor Medalist®250 CLASSIC Medium Duty Cutting and Welding Outfit 0384-2584
• Victor Medalist® STD 250 CLASSIC 0384-2585

Victor sets themselves apart from competitors with a focus on safety. The WH100FC torch handle in the medium duty set comes with built-in flashback arrestors, unlike other brands’ kits which have their arrestors detached or even optional. Victor’s torches offer the check valves and built-in flashback arrestors to give operators peace of mind during their work.

Heavy-Duty Torch Kit

Our most popular heavy-duty torch kit is the Victor Journeyman® EDGE™ Series 2.0. If you go into google and search for “Best Oxy Acetylene Torch Kits,” this kit ranks #1. 

This kit includes:

• Color coded gas hoses
• Oxygen regulator
• Acetylene regulator
• Striker
• Googles
• Tip cleaner
• Torch tip
• Torch handle with check valves
• Cutting attachment
• Heating nozzle
• (3) Brazing nozzles

The heavy-duty torch is what is going to be typically used for large projects such as structural or industrial work, while also being able to tackle the light fabrication jobs. This specific torch outfit comes with multiple brazing nozzles for welding depending on the magnitude of the task. While still staying true to having all the other necessity pieces that have come in the light and medium-duty kits we’ve discussed. 

Other Victor heavy duty options:

• Victor Medalist®350 LP Classic 540/510LP 0384-2710
• Victor G350 510 STD Medalist Classic Outfit 0384-2711
• Victor G350 510 STD Medalist Classic Outfit 0384-2712
• Victor Journeyman 450 Heavy Duty Cutting and Welding Outfit 0384-0807

Like competing medium-duty kits, many brands sell heavy-duty kits for hundreds more than the Victor price, often without built-in flashback arrestors and fewer brazing nozzles. At an affordable price and with a variety of accessories, the power of this Victor Kit comes in its versatility and ease of use.

Which Kit Best Fits Your Project?

To answer the question, it depends on the job. If you are doing some light around-the-house handy work such as HVAC, plumbing or even simple electrical gigs, a Victor light-duty kit is going to be more than enough to complete the project. But, if the work calls for a little more grit such as machinery or light fabrication, then you’ll want to stick with the medium-duty Victor Performer EDGE™ 2.0. Moving up to more intense work such as industrial and structural metalwork requires a heavy-duty kit like the Victor Journeyman. If these specific options don’t suit your needs, each category has alternatives with adjustments to match unique applications.

Find The Perfect Torch Kit With Us!

Regardless of your project, you can find the right Victor Torch Kit for the job on our website! Browse our selection even further here.

When it comes to plasma cutting, Hypertherm is a brand that is synonymous with quality, reliability, and innovation. With a range of plasma cutters and consumables that cater to different needs, Hypertherm has something for everyone, from industrial manufacturers to hobbyists working from their garages. In this blog post, we'll explore the reasons why you should consider a Hypertherm plasma cutter for your cutting needs.

Hypertherm Plasma Cutters: The Pioneers of Innovation

Hypertherm is a company that believes in pushing the boundaries of what is possible with plasma cutting. Their slogan "Shaping Possibility" is a testament to their commitment to innovation. Whether it's their patented consumables or their latest SYNC® plasma cutters, Hypertherm is always striving to make plasma cutting more efficient, versatile, and precise.

Versatility That Fits Your Needs

Hypertherm's range of plasma cutters and consumables is vast and covers a wide range of applications. From the industrial world to hobbyists, Hypertherm has a machine that fits every need. The SYNC® plasma cutters, in particular, bring a new level of adaptability to the playing field. With the ability to quickly and easily switch out consumables to fit your job application, you save time and money. These cartridges also take out the guesswork when it comes to traditional individual consumables such as shields, nozzles, swirl rings, and electrodes.

High-Quality Cutting at an Affordable Price

Investing in a quality plasma cutter is crucial for any cutting application, but it doesn't have to break the bank. The Hypertherm Powermax 30AIR is a plasma cutter that is both affordable and of high quality. This machine has an internal air compressor, making it easy to operate anywhere, and it can be plugged into any 120 or 240 V power source. Additionally, the torches that accompany every machine are also test-fired to ensure quality. If something were to go wrong, Hypertherm honors a 1-year warranty on the torch and a 3-year warranty on the power supply.

Industrial Solutions

In an industrial setting, Hypertherm's range of machines can tackle numerous tasks. Some of these consist of leg work for structural projects. Steel beams or columns for large buildings/structures can require some prep work, which is a fitting job for a Hypertherm SYNC® 105. This machine is also capable of multiple applications such as mechanized cutting, drag cutting, FineCut™, max control gouging, and FlushCut™, giving it high versatility in your workplace. In a sense of time, on most mild steels Hypertherm’s plasma cutting has a significantly higher cut speed than oxy-fuel. This not only saves time but also ensures high-quality cutting without compromising structural integrity.

Shop Plasma Cutters For Every Project At Arc Solutions

Looking for a reliable and high-quality plasma cutter for your next project? Shop our wide range of Hypertherm plasma cutters and consumables. With a commitment to innovation and versatility, Hypertherm has a machine to help you get the job done. Visit our website to find the perfect plasma cutter for your cutting needs!

Whether new to welding or a seasoned veteran, there is a machine for you. But, before purchasing a welder you want to make sure it fits your needs and expectations. Let’s talk about what a Lincoln Electric welder can or can’t do for you.

Your Welding Machine Essentials

First, we can start with the bare necessities to weld from a MIG or TIG perspective.

Things Typically Included

Welder – Generally, a Lincoln Electric machine will come with the essentials. For example, when purchasing a POWER MIG 256, your MIG gun, ground clamp, drive roll, wire guide, and gas regulator with hose kit all come included in the box. On this specific Lincoln Electric MIG welder there is a built-in undercarriage with an easy-load gas cylinder platform.

The model of welder you purchase from your Lincoln welder dealer will dictate if there are more or less items included, such as 1 lb spools of wire to get started or the appropriate consumables compatible with your machine’s gun. If you are TIG welding, purchasing the appropriate TIG rod would be on your list of additional items to purchase.

Additional Welding Products To Purchase

Shielding gas – This item on its own is NOT included with any of the Lincoln welders. For MIG welding, 75% Argon and 25% CO2 is required, and TIG welding requires 100% Argon.

Safety – The two biggest PPE items that are needed are a welding hood (helmet) and gloves. There are a variety of lenses and shades that are adjustable to each consumer and project. The 3350 Lincoln helmet series is equipped with an auto-darkening lens, cutting out the time to take your hood on/off and adjust darkness levels. 

Pliers/Welpers – These are a great purchase for a multitude of reasons! Pliers and welpers can hold the materials you’re welding, cut or pull through MIG wire, and help change and clean out consumables.

Pros And Cons

The next angle we want to look at when searching Lincoln welders for sale are the pros and cons. Whether professional or hobbyist, the first thing most people consider is cost. Compared to the other small machines that you can find at your local hardware store, a Lincoln Electric welder may appear to be pricey. However, the old saying stands true, “You get what you pay for.”

As previously mentioned, with almost all welding machines there are additional items to purchase which also contribute to the cost factor. These items include, but are not limited to: safety equipment, shielding gas and appropriate tools. Depending on your project or job, this list can increase exponentially. Once prepared for the initial cost, a person can usually justify the upkeep of their welding equipment. Lincoln Electric welders are well recognized for their quality and standards, and welding service centers like Arc Solutions Inc. help keep them up and running for as long as possible. Depending on your purchase Lincoln Electric has an excellent warranty program that will help get your registered machine up and running again should something happen.

Much of what goes into a welder’s experience is their knowledge of the trade. Basic things like ensuring proper clarity in a welding helmet by changing your inner or outer cover lens can make a huge difference. Also, dirty surfaces or consumables can taint the quality of your weld. Making sure your consumables and materials are clean will easily improve your weld experience.

Easy On The User

Lincoln welders are great, because as we discussed in the earlier segment, most of the welders come with what you need to get started. Then maintaining and replacing your consumables is easy. This is a definite positive for someone looking to purchase a Lincoln welder that isn’t a ‘seasoned professional’ so to speak, because it gives the hobbyist a leg to stand on. Another user-friendly feature with Lincoln welders is the display screen that helps achieve the proper settings for your project. This display allows the welder to see the voltage, which controls how the weld “wets out.” This feature helps everyone from a hobbyist to an industrial welder when completing a job, thus reiterating its user versatility.

Ask The Right Welding Equipment Questions

When it comes to investing in a Lincoln Electric welder, there are many questions to consider. Do I have the right tools? How much will the proper accessories for my welder and myself cost? If I do purchase a welder, and something breaks, what do I do? We’ve got the answers! Grab what you need for your next project on our pages for consumables,safety equipment,MIG and TIG welders, and machine repair. With our large selection of products, you can research the best option and make the right decision.

Your weld needs are changing and so are your fixtures. In this ever-changing industry shouldn’t your weld fixtures be as adaptable as you? Modular fixturing allows you to do that.

A modular fixturing system is composed of a flat welding table with precise machined holes for the setup of clamps and components on the tabletop. This set up makes fixture components interchangeable and reusable, allowing for the quick accurate set up of new jobs saving time and not sacrificing quality.

Modular fixtures can bring a benefit to almost all work environments; from being able to be used in the smallest to largest factories they also maintain the same accuracy of permanent fixtures at a lower cost. You can also save on the floor space that standard fixtures consume when not being used.

Eliminate the high price of machining new fixtures and the lost value in dedicated fixtures. With the correct modular fixturing system, you can create fixtures on the fly without the worry of costly engineering changes making your permanent fixtures obsolete.

Ready to take the next step? Modular fixturing can come in many shapes and sizes and choosing the correct setup for your needs can be tricky. The experts at Arc Solutions are here to help match up the correct fixturing system that best suits your needs.

Looking for a handheld plasma cutter for your garage or shop? Hypertherm has you covered. Let’s take a look at the Hypertherm Powermax 30 Air.

Don’t let its size fool you, the Powermax 30 Air delivers big performance. This small air plasma cutter — the smallest, lightest handheld plasma cutter in its class — includes its own built-in air compressor. That's right, it's a small plasma cutter with a built-in compressor so you can use the Powermax30 AIR anywhere there’s single-phase power. Just plug it in, attach the work clamp and you’re ready to cut. It's even dual-voltage. It comes with an adaptor so you can plug it into a 120 V or 240 V power source. Regardless of which power input (120 V or 240 V) you choose, We think you'll agree the Powermax30 AIR is the best plasma cutter with built-in compressor available today.

It’s easy to set up and operate.

The built in compressor eliminates the need for an external compressor and filter. It also plugs into 120 or 240 V power.

Superior performance in a compact package

• Patent-pending consumable design enables consistent cutting by optimizing the airflow from the compact, internal compressor
• Quickly cut metal grate or rusted metal without retriggering with the continuous pilot arc feature
• Fast cutting speeds and superior cut quality let you finish jobs quicker, with fewer secondary operations

Exceptional versatility

• Just one tool is all you need to cut a variety of metal types and thicknesses
• Small size and light weight let you take the Powermax30 AIR to the work, rather than bringing the work to the system – an ideal solution for a wide range of cutting applications
• Built to withstand heavy-duty use in the most demanding environments

What you get

• Power supply, AIR T30 hand torch with 4,5 m (15') lead and work clamp with 4,5 m (15') lead
• 240 V/20 A plug with adapters for 120 V/15 A and 240 V/20 A circuits (CSA model)
• Operator and safety manuals
• 1 nozzle and 1 electrode
• Carrying strap

See it in action!

Ready to Buy?

Arc Solutions, Inc. is your go-to expert for welding products. Shop now for your Hypertherm Powermax30 Air

Lincoln Electric’s proprietary liquid crystal display (LCD) enhances the visible color spectrum of the display. Unlike traditional auto-darkening filters, 4C lens technology broadens the color range & hues which can be seen in both light and dark states. This eliminates imperfections and color saturation to create the clearest view of the base material, arc & puddle, while reducing eye strain 4C technology is ideal for a range of industries such as general fabrication, power generation, shipbuilding, structural, offshore and pipeline that use multiple welding processes, including Stick, MIG and TIG. Whatever the task at hand, 4C technology gives you a clear view to productivity and quality.

CHECK OUT THE VIDEO

https://www.youtube.com/watch?v=HvgkdarVeHA

4C™ Lens Technology

WHAT ARE THE 4C’S?

Color Broadens the color range & hues which can be seen in both light and dark states. This eliminates imperfections and color saturation to create the clearest view of the base material, arc & puddle while reducing eye strain.

Clarity

All VIKING® welding helmets feature the highest optical clarity in the industry. This rating is determined by measuring blurriness, distortion, shade consistency and angle uniformity of the auto-darkening welding lens.

Carat

The weight of the 4C® auto-darkening lenses were reduced which improves balance and reduces neck strain to provide all day comfort.

Cut

The propriety technology improves clarity and shade consistency in out of position welding applications

The 4C Lens Technology upgrade to Lincoln Electric’s VIKING® welding helmets – including the 1840 series, 2450 series and 3350 series – improves visibility and reduces eye strain by minimizing the traditional lime green coloring in the helmet view screen.

Ready to Buy?

Arc Solutions, Inc. is your go-to expert for welding products. Shop Now for Lincoln Viking Helmets with 4C Technology

VERSATILE, RUGGED, SIMPLE TO USE.

The POWER MIG® 210 MP® power supply is a multi-process welder for the hobbyist, educator or small contractor who wants to do MIG welding and a lot more, including stick, TIG and flux-cored welding. The push-and-turn digital controls and color display screen make setup and operation intuitive and easy, while the all-metal wire drive and sturdy sheet-metal construction make it rugged and ready for any job in the home or small shop. The POWER MIG® 210 MP® power supply is the ideal MIG machine for the welding novice, with plenty of room to grow as you gain more experience.

ONE POWERFUL MACHINE

Take it Everywhere, Plug in Anywhere.™

• Lightweight and portable - just 40 lbs.!
• Dual Voltage Inputs (120V or 230V) means you can plug into any common power supply

Ready. Set. Weld^®.

• Intuitive push-and-turn digital controls make setup a breeze
• Large color display guides you through the setup process
• Advanced options and settings are simple to access

210 Amps: The power to tackle any job

• MIG: Weld up to 5/16 in. mild or stainless steel or aluminum* up to 3/16 in.
• Flux-Cored (Self- and Gas-shielded): Tackle the biggest jobs
• DC Stick: Handles up to 5/32 in. stick electrodes
• DC TIG: Enabled by Touch Start TIG^® technology

*Spool gun required (sold separately).

Features

• Lightweight and portable just 40 lbs.
• Dual Voltage Inputs (120V or 230V) means You can plug into any common power supply.
• Intuitive push-and-turn digital controls make setup a breeze
• Large color display guides you through the setup process
• Advanced options and settings are simple to access

Here’s What You Get!

• Magnum® PRO 175L Gun
• 10 ft. (3.0 m) (K4076-1) 120V and 230V Input Cables
• Work Cable and Clamp
• Electrode Holder and Lead Assembly
• Adjustable Gas Regulator and Hose
•  Gas and Gasless Nozzles Gun Cable Liner (pre-installed in gun)
• Spindle Adapter
• Sample 1 lb (0.45 kg) Spool of SuperArc® L-56® Mild Steel MIG Wire
• Sample 0.5 lb (0.22 kg) Spool Innershield® NR®-211-MP Flux-Cored Wire
•  0.025 in. (0.6 mm) and 0.035 in. (0.9 mm) Contact Tips
• 0.025 - 0.030 in. (0.6 - 0.8 mm) and 0.035 in. (0.9 mm) Drive Rolls
• 0.030 - 0.045 in. (0.8 - 1.1 mm) Knurled Drive Rolls
• 0.025 - 0.035 in. (0.6 - 0.9 mm) and 0.045 in. (1.1 mm) Wire Guides

Ready to Buy?

Arc Solutions, Inc. is your go-to expert for welding products.

SIMPLICITY WITHOUT COMPROMISE

The Square Wave® TIG 200 is a portable TIG and stick welding machine that lets hobbyists, makers, small fabricators and craftsmen explore their creativity.
It is designed to help expand your welding expertise. As your skills and confidence grow, you can take advantage of the Square Wave TIG 200’s additional functionality. No matter your skill level, you won’t be disappointed.

The Square Wave TIG 200 provides smooth and stable AC TIG welding on aluminum and DC TIG welding on steel, stainless steel and chrome-moly.
A user-friendly interface enables the operators to set it, forget it and weld.

ADVANCED FEATURES YET EASY TO USE

The user interface makes machine setup easy. Available features, such as Pulse, which provides a drumbeat-like rhythm for filler metal deposition, make you become a better TIG welder - faster.

• A Great TIG Machine for Aluminum - For a wider or tighter welding bead, users can easily adjust AC Frequency Control. AC Balance can be adjusted to provide more cleaning action on dirty aluminum or to maximize penetration on thick materials.
• TIG and Stick from One Power Source - The multi-process machine can TIG weld when precision and bead appearance are important. Users also have the advantage of stick welding capability for outdoor work or thicker materials.
• Take it Everywhere, Plug in Anywhere.™ - Plug in the Square Wave TIG 200 where you need it - a standard 120V circuit or 230V for maximum output. Portable and convenient to use, only 46 lb (21 kg).

Here’s What You Get!

• Gas Regulator/Flowmeter and 10 ft. (3 m)
• Gas Hose Kit 200A Stick Electrode Holder
• Ground Clamp and Cable
• 120 and 230V Input Cords
• Foot Amptrol™ - 25 ft. (7.6m) (6 pin) | K870
• PTA-17F TIG Torch Ready-Pak® (12.5 ft 1pc) | K1782-14

Ready to Buy?

Arc Solutions, Inc. is your go-to expert for welding products.

Shop Now for your LINCOLN ELECTRIC SQUARE WAVE® TIG 200

SUPERIOR ARC PERFORMANCE

Forgiving arc and simple tapped voltage control make dialing in your application easy. Smooth arc starts with minimal spatter. Wide 30-140 amp welding output range.

PRECISE WIRE DRIVE

Precision full adjustment drive system reduces chance of wire tangling and crushing. Brass-to-Brass gun connections for enhanced conductivity.

NO HASSLE TOOL-LESS DESIGN

Hassle-free wire spool mounting, wire drive service and polarity changes.

SPOOL GUN CAPABLE

Add the economical Magnum® PRO 100SG spool gun for enhanced aluminum wire feeding performance.

SP-140T WELDING CAPABILITIES

Here’s What You Get!

• Magnum® PRO 100L gun
• 10 ft. (3.0 m)
• Gas Nozzle
• Gas Diffuser
• Cable Liner
• 035 in. (0.9 mm) Contact Tip
• Work Cable and Clamp
• Adjustable Gas Regulator and Hose
• Spindle Adapter
• 0.025 - 0.030 in. (0.6 - 0.7 mm) and 0.035 in.
• (0.9 mm) Smooth Drive Roll for MIG & FCAW

Ready to Buy?

Arc Solutions, Inc. is your go-to expert for welding products. Shop Now for your LINCOLN ELECTRIC SP-140T® WIRE FEEDER WELDER

Is it time to upgrade that old faithful welder you bought at an auction over a decade ago? Every company has that piece of equipment they don’t want to get rid of for a multitude of reasons, but is in desperate need of a welder machine repair, or an upgrade. These reasons could be sentimental: an employee’s favorite, fear of change, false belief of cost savings or almost anything else. Let’s take a dive in and see if it’s time to finally pull the trigger and upgrade your tools.

A New Welding Machine Saves You Power And Money

An often overlooked reason to upgrade is reflected in power savings. Let’s use a few Lincoln machines and calculate the power savings of a traditional transformer machine vs. a newer inverter machine. In the chart below, a calculation was done for one production shift of power savings with a new Lincoln Electric inverter style machine (Powerwave S500) and an older Lincoln Electric transformer style machine (CV-400).

When the $4.95 per shift is multiplied out to a full year (estimated 260 working days) this equates to $1,287 per year. When multiplied by 3 shifts that grows to $3,861 cost savings per year.

In addition, many electrical companies will provide discounted rates or rebates for companies who convert to equipment that requires less power draw. If you are switching to newer, more efficient machines this would be a great option to explore.

Improve Your Weld Quality With Advanced Welding Technology

After power savings comes weld quality. Welds that used to be difficult or even impossible may now be very feasible to do. Each manufacturer has their own terminology, but from a high level the general ideas are similar. The benefits of newer equipment include better gap filling, higher deposition rates, more aesthetically pleasing welds (prettier welds), decreased porosity, capabilities to weld exotic materials, different transfer modes to help when welding out of position, and constant penetration. These can be broken down even further. For instance, high deposition rates mean more weld metal gets put down in a given amount of time. It also means that less overall heat goes into the base metal and this helps to minimize distortion.

The advanced waveforms make the welding easier so less technical operators are required. All welding requires is someone who understands the welding process to dial in the parameters. However, once the new machines are dialed in, they weld a wide range of thicknesses using the synergic setting. Now the operator is only turning one knob and the machine compensates for the rest. Existing programs can even be saved so that it takes the guesswork completely out of a parameter adjustment. If applicable, the welder can even record the real weld data to save and refer back to in the future.

Save Space And Strain With A New Welder

The size and weight of welders have decreased significantly with technology. Older machines, like the CV-400 weigh in at 383 pounds. The inverter based Powerwave S500 is capable of 25% more output but only weighs 68 pounds. This creates less strain on operators who move their equipment around. It also saves valuable floor space because the footprint of the machine is significantly smaller.

A final tick against the older machines is repair parts. As product lines become older they are no longer supported by the original equipment manufacturer (OEM). If and when the older equipment breaks down, being able to quickly get the machine repaired and back into production becomes difficult.

We’ve Got Your New Welding Equipment!

If you would like to learn more about new welding equipment, reach out to Arc Solutions, Inc. We have technical sales employees who are happy to help educate you on the pros and cons of major industrial welding brands. We will also provide you with a quote to replace your equipment if desired. If you have a welder that needs service work, our team of authorized service technicians will get your machine fixed and back on your floor ASAP. Contact us today to upgrade your welder and your workflow, and shop our equipment in our store!

Robotic Welding: Maximizing Efficiency in Manufacturing Facilities

Manufacturing facilities have increasingly integrated welding robots into their production processes to improve efficiencies and generate more profits. With the use of robotic welders, companies can produce more products using the same resources. However, it's not enough to simply have a robot in place. Companies need to focus on increasing robot speeds and decreasing cycle times to maximize their output.

Cycle times are measured by timing how long it takes to load a part, have the work done to it (i.e., welded), and then unload it. By reducing the cycle time, the robot can process more parts in the same amount of time, thereby increasing production. For example, reducing the cycle time by just a few tenths of a second per part can result in significant gains over time.

In this article, we will explore various ideas to increase robotic welding speeds and decrease cycle times. By implementing these ideas, companies can maximize their production output and generate more profits. But first, we’ll review the benefits robots bring to production facilities at a foundational level.

The Benefits Of Robotic Welding

Robotic welding is a great investment for manufacturing facilities because it offers numerous benefits, including increased accuracy, consistency, and productivity. Welding robots are designed to make the same precise welds over and over again, ensuring that the finished product is of the highest quality. Unlike human welders, robots do not suffer from fatigue or distractions, which means that they can maintain a high level of accuracy and consistency throughout the day.

Another significant benefit of robotic welding is increased productivity. Welding robots can work continuously, 24/7 if needed, and can complete welds much faster than a human welder. This means that more work can be completed in a shorter amount of time, increasing the overall productivity of the facility. Additionally, robotic welding can help reduce labor costs since one operator can oversee multiple robots at the same time.

In addition to accuracy, consistency, and productivity, robotic welding is also beneficial for the safety of workers. Welding can be a dangerous job, especially when it involves high temperatures, fumes, and hazardous materials. By using welding robots, companies can reduce the risk of accidents and injuries to their workers. Welding robots can withstand dangerous environments where it would be hazardous for humans to work, such as tight spaces or areas with harmful chemicals or radiation. This makes them a great addition to manufacturing facilities looking to increase efficiency.

So, how can a manufacturing facility that already has robots continue to achieve maximal efficiency? It all starts with understanding the physiology of welding automation at its core.

The Physiology Of Welding Automation

Welding automation systems can have both positive and negative impacts on workers. When used correctly, automation can make jobs and lives easier, while increasing productivity and reducing errors. However, if automation is not implemented properly, it can demoralize workers by taking away their jobs or making them feel unimportant.

To ensure that automation is being used effectively, it is important to maintain a 1:1 ratio between the amount of work being done by the robot and the operator. This means that while the robot is performing a task, the operator should have a task to perform as well. Additionally, factories have found that slowing down equipment to match operator speeds can actually increase production rates by allowing operators to keep up with the pace of the work being performed. The remainder of this article is for the opposite problem and is focused on speeding up the robot so that the operator isn’t wasting time waiting for the robot.

Know Your Parts

It is important to double-check that the robot is not being taught a strange path or a slower speed on purpose. If this is the case, the robot may not be performing at its optimal speed or efficiency. Manufacturers should speak with the appropriate parties, such as engineers or robotic programmers who originally wrote the program, to ensure that the robot is functioning properly. Having a reliable welding automation specialist on your side will keep business running smoothly.

Manual Welding vs. Robotic Welding

While manual welding has been the standard for decades, robotic welding is becoming increasingly popular due to its efficiency and cost-effectiveness. Manual welding requires skilled labor and is often more time-consuming than robotic welding. Human welders may also be more susceptible to errors, leading to the need for rework, which can be time-consuming and costly.

Robotic welding, on the other hand, can perform welds much faster and with higher accuracy than manual welding. Welding robots can also work continuously without breaks or distractions, which means that more work can be completed in a shorter amount of time. While the initial cost of investing in robotic welding technology may be high, the long-term savings in labor costs, reduced errors, and increased productivity make it a cost-effective investment for many manufacturing facilities.

Speed Up The Air Moves

One way to increase the speed of a welding robot is to speed up the air moves. The air moves refer to the robot's movements between welds, which are controlled by air pressure. Robots typically measure air move speed in a percentage with 100% being top speed for air moves. By increasing the air move speed, the robot can move faster between welds, reducing the amount of time needed to complete a weld cycle.

Keep in mind that increasing the air move speed too much can have a negative impact on the quality of the weld. Higher air move speeds can cause the welding torch to move too quickly, which can result in missed welds or less precise welds. It's crucial to find the right balance between speed and accuracy to ensure that the finished product is of the highest quality.

Adjust The Part Clearance Spacing

Another way to speed up a welding robot is to adjust the part clearance spacing. Robots go to the exact same spot and follow the exact path every time, so moving the air move points closer to the fixtures, clamps, or other parts can save time. By reducing the distance that the robot needs to travel between welds, the overall cycle time can be reduced, allowing the robot to complete more welds in less time.

However, it's important to make sure that the part clearance spacing is adjusted carefully to ensure that the welding torch doesn't collide with other parts or fixtures. Collision can damage the robot or the part being welded, resulting in costly repairs or replacement.

Modify The Order Of Welds

As we mentioned earlier, robots follow the exact same path every time they weld. By starting on one side of the part and working towards the opposite side, we can save time and reduce cycle times. This approach is based on the concept that the quickest way to get somewhere is in a straight line. By reordering the welds, we can make sure that the robot moves in a straight line, reducing the time it takes to complete each weld.

Another way to modify the order of welds is to arrange them in groups based on their size and complexity. By tackling the larger, more complex welds first, the robot can work on them without the risk of collision or interference from other welds. Once the larger welds are complete, the robot can then move on to the smaller, less complex welds.

Embracing Robotic Welding For Increased Efficiency & Profitability

Robotic welding has numerous benefits for manufacturing facilities. It increases accuracy, consistency, and productivity, while also reducing the need for rework. It can also improve safety by welding in environments that are dangerous for human workers.

To make the most of robotic welding, it is important to understand the physiology of automation and how it can be demoralizing to workers if not used properly. Operators should have 1-minute worth of work while the robot is doing 1-minute worth of work, and factories have seen increased production rates by actually slowing down their equipment to match operator speeds.

It is also important to know your parts and double-check that the robot isn't taught a weird path or a slower speed on purpose. Speaking with the appropriate parties such as engineers or robotic programmers who originally wrote the program can help ensure that the robot is working optimally.

Finally, to increase efficiency and generate more profit, we must focus on increasing robot speeds and decreasing cycle times. We can do this by adjusting the air move speed, modifying the part clearance spacing, and modifying the order of welds. By implementing these strategies, we can make the most of our robotic welding systems and stay competitive in today's manufacturing landscape.

Arc Solutions: Your Trusted Welding Robot Expert

Looking to streamline your welding processes and increase productivity? Look no further than Arc Solutions, Inc! Our team of robotic welding specialists has the knowledge and expertise to keep your facility operating at unparalleled efficiency. From reducing wasted motions to faster turnaround times, we can help your team work more efficiently and effectively.

But we don't just stop at improving your current processes. We also provide turn-key solutions to meet and exceed your fabrication needs. So whether you're looking to optimize your existing workflow or implement a brand new system, you’re in the right place.

Don't wait any longer to streamline production. Contact us today to see how we can help you achieve your goals.

When making an investment into automation, it is important to calculate your Return On Investment (ROI). The term ROI is a fancy way of saying how long it will take until this equipment makes me more money than it cost me. ROI can be calculated many ways and must meet different requirements for different companies, but below is a good start to cost justifying your purchase.

The first and easiest thing to calculate are direct cost savings. Direct costs are costs that can actually have a dollar value put on them. Purchasing agents love direct cost savings because they look great on paper. The most expensive direct cost in most welding jobs is labor: their hourly wage and the overhead associated with each worker. The overhead includes cost like bonuses, vacation time, holiday pay, sick days, insurance, HR cost, etc. The typical labor and overhead cost is three times the hourly wage of the employee meaning that a $20/hr employee actually cost the company $60/hr to have on staff. When robots are introduced, the very conservative numbers are that one welding robot will double the output of a manual welder, but in reality the production rate of a robot is typically triple that of a manual welder. The actual productivity of a robot can be calculated using a cycle time analysis formula. Contact Arc Solutions, Inc for a cycle time analysis on your parts if you are interested in working towards automation.

Consumables are another direct cost savings. Contact tips in robots will weld more parts than contact tips in manual applications. This is because the contact tip to work distance is more accurately maintained to create a smoother arc and less spatter. Weld cleanup and part rework is also reduced because the spatter is much more controlled and the robot is far more accurate than a human can be. As you well know, the cost of grinding wheels and labor associated with cleanup and rework is a number that adds up quickly and adds no value to the part. Over welding parts is a common human error also. Welders will error on the side of caution and create bigger welds than required when welding manually. With robotics the exact weld size is controlled so it speeds up travel speeds, lowers the amount of wire consumed, and uses less shielding gas all while increasing the quality of the weld.

Indirect cost savings are a little more difficult to put a number on. The biggest indirect savings from a robot is weld quality. Robots make perfectly consistent movements every time so you can be confident that the weld is the right size and in the right location. You can also be confident that welds didn’t get skipped over by human error. Weld spatter and wire stubs being cut off at the end of the torch are common when manual welding. However, with robotics this can be closely controlled and a higher percentage of the purchased wire actually becomes weld metal and not wasted material that needs swept up off of the floor.

In today’s market, no one is looking to get rid of employees, but instead the exact opposite is happening. Rather than hiring employees, the addition of cobots and robots allow you to free up and move existing employees to other jobs in the shop. On a similar topic, the employee training required as a robot operator is far less than that required as a welder. The pay scales of robot operators vs. manual welders reflect the necessary skills for the job as well with operators typically earning a lower hourly wage than welders. The one thing robots do require is someone with the proper training to program them. First time robot purchasers typically get free training for one person. The standard length of training is four (4) days. It is important that the robot programmer has some welding experience as well as being comfortable with computers. Cobots however are much less technical when it comes to programing. With the most recent programming methods being icon driven; a production welder who is comfortable with a smart phone can be programming the cobot on their own with only a few hours of training.

There are a few options for getting automation into your shop. The traditional way was a full purchase of the equipment from a number of integrators. Another option is rental or lease to own plans. These plans allow customers to get introduced to automation without having such a large upfront risk. Arc Solutions has rental plans available for both cobots and traditional robots. Our lease to own plan has a percentage of the lease price being applied towards the purchase price of the equipment if you choose to buy. We also offer financing options for customers who are looking to buy equipment.

Reach out to Arc Solutions, Inc. today if you would like to explore your automation options. We can be contacted by phone at 419-542-9272 or via email at office@arcsolinc.com

Traditional Robots Vs. Up and Coming Cobots

Automated welding in the manufacturing industry has always been most sought after for high volume, low mix weldments. Automation began as “hard automation” where a machine was built to do only 1 specific job and then evolved into “flexible automation”. Flexible automation as we know it today consist of multi-axis weld robots (typically 6 axis) that can be programmed through a teach pendant for hundreds of different jobs. The first of these programmable robots were developed in the 1960s and have advanced with technology ever since. Fully automated robots today move at lightning speeds to cut down on air move time, but require multilevel safety features including a full fence to keep humans protected. Cobots (collaborative robots) are now making their way into this automation scene because they are designed to collaborate (work alongside of) a human operator. Since the fencing has been eliminated, cobots take up a much smaller footprint. In fact, the Cooper™ Cobot option from Lincoln is on a wheeled cart so that it can be pushed anywhere its needed in the shop.

Why invest in a Cobot?

Cobots have brought an exciting new face to the world of robotic welding. The technology helps in many facets. Programming is now completed with a tablet instead of a traditional robotic teach pendant. This makes the device extremely user friendly and even more inviting for the younger generation. The programming side is icon driven and built around drag and drop techniques so it is very quick to learn. Even beyond that, the cobot can be programmed by physically moving it with your own hands to the desired location. Then you can hit one button to save the point, drag it to the next location, save the new point and so on. These features allow welders off the production floor to be taught to program in hours. With traditional robots, companies had to hire programmers who knew how to program a robot and how to weld. As those in the manufacturing business know, that is a difficult combination to find. With the ease of programming cobots, everyday welders can now teach cobots.

What companies offer cobots?

There are a handful of companies that currently offer welding cobots. The professionals at Arc Solutions, Inc. have chosen to team up with Lincoln Electric for collaborative robots. Lincoln Electric and Fanuc have a long standing history of working together for arc welding automation. Through decades of knowledge and know-how, the two companies have launched the Lincoln Cooper™ Cobot. This system is an off the shelf part number that utilizes Fanuc’s R30iB mini controller. Those with a background in automation know the R30iB controller and its power in the automation world. The controller chosen for the Guru package still contains the programming features that automation programmers have come to depend on. The companies believe so wholeheartedly in their own equipment that Fanuc is promoting 8 years zero maintenance on the arm and Lincoln offers a 3-year warranty on the welding power source.

Is a cobot right for everyone?

No, we don’t believe they are. Like everything else in life there are tradeoffs. To account for human safety, cobots move slower than traditional robots. This increases the air move time thus increasing cycle time when compared to a traditional robot. If you are looking to weld 100,000 of the same part every year for 5 years, then a traditional robot is still your ticket. However, if you are more job shop oriented and build 50 parts of multiple different items you should look into cobots. The amount of time you lose with slower air moves would easily be justified by the time savings of programming. A current downfall of cobots are lack of weld positioners. With traditional robotic weld cells part positioners are used to rotate the welds in the optimal orientation. Cobots cannot do that yet. Collaborative positioners have not been tied to collaborative robots yet, BUT the clock is ticking and the technology will soon follow to allow cobots and positioners to work in conjunction.

What kind of weld quality can I expect from a cobot?

Weld quality from robots and cobots is nearly impossible to beat. Once the weld parameters have been dialed in (which manual welders are typically skilled at doing), the welds are extremely consistent. Robots and cobots both go to the exact same location and travel the same speed every time. This eliminates weld quality issues due to operator fatigue or trying to rush a job. It also helps to eliminate spatter since all the variables remain constant. The Guru package has a built in software package that locks in the torch angle as well. This allows for the first weld point to be taught and the torch angle to remain consistent for the entire length of the weld. Software packages like Touch Sense can be purchased in addition. Touch sense uses the wire to go around and locate the orientation of the part if there are consistency issues. On thick plate there is a software called Through the Arc Seam Tracking (TAST) that uses voltage measurements to maintain the programmed path on joints such as T joints.

How does cobot pricing relate to traditional robotic cells?

Cobots and simple one or two station traditional robotic cells are priced very similar to one another. The dollars saved on safety gear like fencing and light curtains are now used in the technology to make the arm collaborative. The Fanuc CRX arm that the Lincoln cobot package offers has sensors in each of its 6 axes. These sensors are what stop the cobot arm immediately when it hits something in its path. If the cost of buying a cobot seems daunting, Arc Solutions offers a leasing/rental program. In fact, both cobots and traditional robots can be used on a rental or a lease-to-own program that helps take risk away from the purchaser.

Are there options to customize a cobot?

With the Guru cobot package there are all kinds of options. The system comes standard with a Powerwave R450 powersource and a Lincoln Magnum 550 amp gun. The gun can be upgraded to a 650 amp water cooled option. Additional options like fume extraction, fabrication tables, thick plate software which includes multipass software, touch sense software, and different length arms are available. The standard reach arm is 49 inches and the long reach arm goes out to 55 inches. This is measured from the center point of the robot. This means the reach is actually 49/55 inches in each direction from the center. Reach out to Arc Solutions Inc. for a full list of cobot options and arm lengths!Arc Solutions has a full technical staff well versed in the welding and cutting industry. Please feel free to call us at 419-542-9272 or email office@arcsolinc.com for sales and technical assistance.

Metal cutting isn’t a job for the weak, but rather a job for the ambitious. Mechanical methods aren’t always the best option for cutting metal. In recent years, plasma cutting technology has grown to become the go-to for professionals, contractors, and DIYers across the United States.

But why? 

Introducing plasma cutting equipment into your fabrication process only enhances the final outcome. Unlike mechanical cutting, plasma cutting encompasses fine tuning precision qualities that promise a clean cut and even sharper edges. Read on for key advantages of plasma cutting technology and why you should consider this industry favorite if you’re not already. 

How A Plasma Cutter Works

Plasma is the fourth state of matter. The one our elementary science teachers most likely skipped over because nearly impossible to point out in plain sight. The fuel source for The Northern Lights and lightning, plasma makes up about 99% of the visible universe. 

So, how can plasma cut metal?

Plasma cutters take electronically conductive gas and transfer the energy from a power supply to any conductive material, which creates the clean, fast cuts that are so satisfying to make. 

The Advantages Of Plasma Cutting Technology

Plasma cutting tools are not only precise, as previously mentioned, but they are constantly evolving. Their most recent innovations make them cost-efficient and more accurate than ever before. Most fabrication operations can benefit from the advantages of plasma cutting technology. It’s simply a matter of finding what works best with your setup. 

Plays Nice With All Conductive Metals

Material compatibility is essential when investing in cutting equipment. Plasma cutting works on a variety of materials such as:

• Copper
• Titanium
• Steel
• Iron
• Alloys

Hits Every Angle

Oddly satisfying, plasma cutting can cut any shape, angle, or curve. The beam of light is as smooth as putting pen to paper. This alone opens a realm of possibilities for taking on new projects.

Less Maintenance, Lower Costs

The experts at Arc Solutions swear by the value plasma cutting technology offers. They’re low maintenance and rarely require service. When the time does come for a routine tune up, we have techs on standby ready to get you back up and running.

Keep Up With Demand With Plasma Cutting Tools

Fabrication professionals across the country rely on plasma cutting technology to keep up with increasing demand. Not only is it easy to implement into existing workflows, but it expands potential for taking on a wider variety of projects that require precision cutting. Tackle any curve, angle, or metal with reliable plasma cutting. 

High Quality Equipment That Makes The Cut

If you have questions about how to select the right plasma cutter for your project, Arc Solutions is here to help. We bring over 100 years of experience to the table to get you the best product for the best deal. Shop our inventory of plasma cutters today or contact us directly to talk to a local expert.