Thermal Engineering
When customers invest in robotic welding automation, they often focus on the result: improved productivity, consistent quality, and reliable performance. However, behind every successful robotic welding system is a detailed engineering process that begins before equipment arrives on the floor.
According to Mark Latvala, Sr. Engineer – Thermal Applications, the role of an application engineer starts once a sales team identifies an opportunity. From there, the engineer gathers information and develops a proposal for a robot system capable of producing the customer’s parts at the desired production rate and quality. Just as importantly, the engineer must determine materials, labor, and cost associated with the project.
Understanding Customer Requirements
One of the first steps in developing a thermal application solution is gathering the information needed to understand the customer’s production goals and define the project scope. Latvala considers factors such as production volume, available manufacturing time, part size, weight, rotational inertia, and available floor space. He also requests part drawings, models, quality specifications, and plant layouts while asking how parts will enter and leave the robotic system and assessing the customer’s level of robotics experience.
Together, these details help determine the appropriate robots, positioners, hardware, and system layout while ensuring the proposed solution fits within the customer’s existing manufacturing process.
Solving Engineering Challenges
Large or complex parts can present additional engineering challenges. Before a system is built, engineers must verify that the robots can reach every required location throughout the welding process. Latvala uses tools such as AutoCAD, Solid Edge, and MotoSim to develop and evaluate the proposed robotic workcell. These tools help identify potential reach or layout issues during the concept phase rather than after installation.
From Concept to Proposal
Once the project scope is defined, Latvala develops a robot cycle-time estimate to determine how long the robot will take to complete the required process. He also identifies the hardware needed for the application. Depending on the project, this may include customer-specified end-of-arm tooling, positioners, robot tracks, sensors, or specialized equipment. When necessary, vendor quotations are obtained to determine any additional costs with third-party goods or services.
Once technical requirements are established, robot system layout drawings are created, costs are compiled, and labor hours are estimated. A proposal draft is then prepared and reviewed by the engineering team. Following any required revisions, pricing is reviewed with sales and approved by management before the proposal is finalized and delivered to the customer.
Performance, Value, and Customer Expectations
When designing a thermal application solution, the primary objective is to meet all performance requirements while delivering the lowest-cost system or highest overall value to the customer. Latvala notes that while energy efficiency is not often a deciding factor during the purchasing process, robotic systems can still be programmed to reduce energy consumption during idle periods through available system features.
Managing customer expectations is also an important part of the engineering process. A common misconception is that robots can operate entirely on their own. In reality, robots perform only the tasks they have been programmed to do. For example, if a weld is misplaced the issue is often due to changes unrelated to the robot itself. That may be a part positioned slightly different than before, a joint location moved, or even issues with the welding equipment.
Another misconception is that custom automation solutions can be developed instantly or without much labor. Latvala explains that designing and implementing custom hardware requires engineering effort, testing, and problem-solving. Complex projects sometimes require additional time to resolve issues and ensure the final system performs as intended.
Looking to the Future
Latvala has seen continuous improvement in thermal applications technology. Welding power supplies now offer improved characteristics in Motoman’s Arc systems, while sensor technology provides greater resolution and tolerance for imperfect manufacturing conditions. These advances allow engineers to develop increasingly capable robotic welding systems. He also expects artificial intelligence to become more integrated with robotic welding applications in the future. While AI may assist with welding processes and robot programming, it will still require training and application expertise to deliver effective results.
Conclusion
The development of a robotic welding solution involves far more than just selecting a robot. It requires a thorough understanding and evaluation of customer goals and technical requirements. It also requires detailed system design and close collaboration across engineering, sales, and manufacturing teams. Through this process, thermal application engineers help create solutions that meet production goals while addressing the unique challenges of each application.
Information from interview conducted with Mark Latvala Sr. Engineer – Thermal Application, on 7/17/26 by William Diaz.
Mark Latvala is a Senior Application Engineer
