# Orbital-Based Automatic Multi-Layer Multi-Pass Welding Equipment for Small Assembly Plates
## 5 Multi-Layer and Multi-Pass Welding Experiments
### Comparison of Welding Experiment Results and Benefits  
Taking a single plate's web and panel multi-layer and multi-pass processing experiment as an example, a comparison is made between the rail-type automatic welding equipment and manual welding. The welding performance comparison analysis is shown in Figure 38. The data in Figure 38a,b include the overall weld seam formation rate of the sub-assembly plate's panel and web groove, welding material consumption, and welding efficiency. After ten experiments, the formation rate of the rail-type automatic welding equipment is stably higher than that of manual welding by 11.48%, the total material consumption is reduced by 13.4%, and the unit material consumption is reduced by 13.5%. The comparative analysis results of the overall efficiency, production efficiency under working conditions, and processing costs between automatic welding and manual welding are shown in Table 14.  
Under the same production conditions, following the data in the previous table, comparative experiments were conducted on sub-assembly panels and webs with different gaps using automatic welding and manual welding. From Table 15, it can be seen that when the gap is 4 mm, the efficiency increases by 7.35%, and time is saved by 10.2%; when the gap is 5 mm, the efficiency increases by 10.7%, and time is saved by 7.39%. Therefore, it can be concluded that automatic welding is more efficient than manual welding and also saves time costs. \begin{table}
\begin{tabular}{c c c c c} \hline \hline \multirow{2}{*}{**Welding Method**} & \multirow{2}{*}{\begin{tabular}{c} **Material Consumption** \\ **(KG)** \\ \end{tabular} } & \multirow{2}{*}{\begin{tabular}{c} **Unit Consumable** \\ **(KG/M)** \\ \end{tabular} } & \multirow{2}{*}{\
\begin{tabular}{c} **Ratio of Briquetting** \\ **(\%)** \\ \end{tabular} } & \multirow{2}{*}{
\begin{tabular}{c} **Number of** \\ **Experiments** \\ \end{tabular} } \\ \hline Automatic welding & 1.7765 & 0.845 & 98.699 & 10 \\ Manual welding & 2.052 & 0.977 & 87.219 & 10 \\ \hline \hline \end{tabular}
\end{table} 
Table 14: Comparative analysis of welding performance. Figure 38: Welding performance comparative analysis diagram. Subsequently, as shown in Table 16, taking 1000 plates with the same specifications and processing conditions as the above single-plate experiment as an example, an economic benefit comparative analysis of the two processing methods was carried out. The total weld seam length is 450 m. In the analysis conditions, both the rail-type automatic welding equipment and manual welding are configured with two welders working in shifts, with a daily working time of 12 hours. Among them, the workers operating the automatic welding equipment are junior welders with a daily wage of 150 yuan, and the workers performing manual welding are senior welders with a daily wage of 230 yuan. From the analysis results in Table 16, it can be seen that the labor cost of automatic welding is reduced by 41.4% compared to manual welding, and 16.7% of the time cost is saved. The schematic diagrams of the results for automatic welding and manual welding are shown in Figure 39a,c,e and Figure 39b,d,f, respectively. As seen in Figure 39, the weld seam appearance welded by the orbital automatic welding equipment is more uniform, with better consistency and minimal defects. The formation and coloration are aesthetically pleasing and meet the required standards. Table 17 provides a detailed comparative analysis of the welding effects between automatic and manual welding under the condition of a single workpiece. The labor and material costs in Table 17 include the labor and consumable costs for fully processing a single sheet of the test panel. Welding current and voltage can be freely selected within the given range according to the actual welding environment on site. Welding time includes both the welding operation time and the buffer time between each welding layer or pass.