Robotic Welding (Part 2)

There are two popular types of industrial welding robots. The two are articulating robots and rectilinear robots. Robotics control the movement of a rotating wrist in space. A description of some of these welding robots are described below: Rectilinear robots move in line in any of three axes (X, Y, Z). In addition to linear movement of the robot along axes there is a wrist attached to the robot to allow rotational movement. This creates a robotic working zone that is box shaped. Articulating robots employ arms and rotating joints. These robots move like a human arm with a rotating wrist at the end. This creates an irregularly shaped robotic working zone.

There are many factors that need to be considered when setting up a robotic welding facility. Robotic welding needs to be engineered differently than manual welding. Some of the consideration for a robotic welding facility are listed below:

Accuracy and repeatability Number of axes Reliability Fixtures Programming Seam tracking systems

Maintenance Controls Weld monitors Arc welding equipment Positioners Part transfer

A robotic welding system may perform more repeat ably than a manual welder because of the monotony of the task. However, robots may necessitate regular recalibration or reprogramming.

Robots should have the number of axes necessary to permit the proper range of motion. The robot arm should be able to approach the work from multiple angles.

Robotic welding systems are able to operate continuously, provided appropriate maintenance procedures are adhered to. Continuous production line interruptions can be minimized with proper robotic system design. Planning for the following contingencies needs to be completed:

• Rapid substitution of the inoperable robots.
• Installing backup robots in the production line
• Redistributing the welding of broken robots to functioning robots close by

(AMC-Weldingengineer.com)

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Robot welding

When should robots be used for welding?

A welding process that contains repetitive tasks on similar pieces might be suitable for automation. The number of items of any type to be welded determines whether automating a process or not. If parts normally need adjustment to fit together correctly, or if joints to be welded are too wide or in different positions from piece to piece, automating the procedure will be difficult or impossible. Robots work well for repetitive tasks or similar pieces that involve welds in more than one axis or where access to the pieces is difficult.

Why robot welding?

The most prominent advantages of automated welding are precision and productivity. Robot welding improves weld repeatability. Once programmed correctly, robots will give precisely the same welds every time on workpieces of the same dimensions and specifications.

Automating the torch motions decreases the error potential which means decreased scrap and rework. With robot welding you can also get an increased output. Not only does a robot work faster, the fact that a fully equipped and optimized robot cell can run for 24 hours a day, 365 days a year without breaks makes it more efficient than a manual weld cell.

Another benefit of automated welding is the reduced labor costs. Robotic welding also reduces risk by moving the human welder/operator away from hazardous fumes and molten metal close to the welding arc.

What welding processes are suitable for robot welding?

Most production welding processes can be used in automated applications. The most popular, used in perhaps 80 percent of applications, is the solid wire GMAW process. This process is best for most high production situations because no postweld cleanup is required. (Robot-welding.com)

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