Welding robots

Overview welding robot systems

Highest Quality Welding Robots Solutions

The welding robots process is improving the weld with robotic welding. Therefore, the most well-known welding processes automation is arc welding, laser welding, and plasma cutting welding, TIG, and spot-welding robots. Besides, industrial robots always increasing production speed, but the main feature is that robots produce quality welds and reducing errors. 

Additionally, automation systems help the manufacturer offer the staff a new position within the company as robot operators. In Fact, by adopting welding automation processes, companies are becoming more competitive, provide high standards of welding. Actually, we have a great selection of welding robots for sale.

Top Types of Welding Robots

Although this is far from a comprehensive list, the following are some of the most common types of welding robots:

  1. Arc Welding:  This is a welding process that uses primarily electricity to join metal to metal. The car manufacturing industry was one of the first industries to use largely this type of welding.
  2. Resistance Welding: Delivering energy savings and efficiencies. It is current is passed between two metal pieces of metal. Thus, the heat will join two pieces together. This type of robot is the most economical form of robotic welding and is best for heat-treating projects.
  3. Spot Welding: This welding process can even join aluminum or other raw materials that are not normally weld.

Advantages of using Six-Axis Robot for Welding

There are some clear advantages of using a six-axis robot for welding:

  • The welding environment is not ideal for humans, but the welding flash, heat, or fumes do not affect the robot.
  • Once programmed the robot path will be very repeatable and consistent.  Each job that runs on that cell will have the same good quality.
  • Unlike a human welder, the robot won’t require any breaks and therefore can run if required for 24 hours 7 days a week.

Programming Robots

Manual mode allows all access for programming of the robot path trajectories when necessary but in this case, it will limit the speed to 250mm per second. Alternatively, it is possible to have a key exchange system. It will prevent the staff to keep shut in the cell when the process starts. One such popular system is the Fortress Lock system shown below. In this case, there is a master key that allows the release of one or more cell access keys. Unless all the cell access keys are back the system cannot be enabled in automatic mode.

Robotic Welding Systems

Robot welding systems can help to protect staff from hazardous jobs and robots handle dangerous tasks. While the ultra-fine and extremely light fine dust particles represent a threat to the manual welders, the robots are able to work in this environment without any risk. Please see below our welding robots for sale list. Also, manufacturing robots are suitable for lifting heavy loads without any work incident.  

Likewise, we offer tailored packages based on budget and requirements. For example: ABB Robots, KUKA Robot, FANUC and Motoman. Also, we provide full integration from helping to select the right robot to the completion of the project. Nevertheless,  our vast expertise and many years of robot integration experience, allow us to know exactly where to find affordable welding robots for sale.

 

Main Elements of Robotic Welding Cell

Having talked about some of the considerations to take into account we will now have a look at the main elements that make up the majority of robotic welding cells. Firstly, we have the six-axis robot itself. Likewise, considerations here are for payload and envelope or reach. Most welding systems tend to have a lightweight torch and the reach required that denotes the robot type. Because of the services brought to the torch it is also a good idea to take into account the drag on the wrist that these may introduce particularly if there is a lot of wrist re-orientation during the welding motion.

Two Welding Robot Stations

It is common for installations to feature some form of a two-position turntable. This will allow removing the completed parts and new parts reloaded whilst the robot is welding on the parts previously loaded.  In some cases to have access to the welding torch or to keep the weld path horizontal, the integrator may need to re-orientate parts.

1. Two Position Turntable for Welding operations

In this situation, you can use an integrated positioner, whereby the axes of the positioner are controlled directly by the robot. In the case of this type of workpiece presentation, there will again be two stations one for the operator to load and unload and the other for the robot to carry out the welding operations. However, the rotational axis, in this case, will be part of the robot’s own movement. As a result, there will be two or three additional axes for each station allowing the robot to rotate the part both horizontally and vertically.

2. Integrated Turntable for welding tasks

As mentioned previously there is usually some form of part presentation turntable the most basic being a simple two-position device that has two stations one for the operator and the other for the robot. The operator can either drive the turntable into position by an output from the robot itself driving a simple motor or by the operator turning the turntable by hand and the robot controlling the rotation via a locking shotbolt.

Where it is required that the part is tilted or rotated during the welding process, it will require an integrated turntable.  Consequently, these can have different configurations and different numbers of axes depending on the requirements for the movements necessary.

3. Torch and welding equipment

Fitted to the robot will be the torch and associated equipment along with a weld controller. As standard, we favour a Fronius setup. The central control and regulation unit of the power sources is coupled with a digital signal processor.

Therefore, the central control and regulation unit and the signal processor control the entire welding process. In addition, the data is measure continuously during the welding process, and the device responds immediately to any changes. Additionally, control algorithms ensure that the desired target state is maintained.

This results in:

  • A precise welding process.
  • Exact reproducibility of all results.
  • Excellent weld properties.

4. Tip Cleaning

An integrator will mount a tip clean stand near the robot but out of the work. This allows to carry out  several actions as follow: Firstly, the robot will move over to the wire cut device which will trim the welding wire to the correct length.

Second, as the nozzle of the torch will suffer a build-up of weld spatter over time there is a reamer fitted to the tip clean which will move up inside the nozzle to clean the tip of this build-up. Likewise, the removed spatter will fall into a removable collection dish mounted under the reamer. Lastly, the robot moves the torch over to the parting agent spray system. Then, it will spray a parting agent up into the newly reamed nozzle.

5. Fixturing And Clamping

The integrator requires some form of fixture jig for mounting the part.  We normally supply the work table but not the fixturing itself. Therefore, the customer supply this part.  Please bear in mind that the quality of the jigs that hold the parts prior to welding is very important for the quality of the finished job. The parts need to be located with high repeatability and also rigidly to ensure that no movement takes place during the welding process.

Secondly, the clamping arrangement is very important to avoid having clamps and supports that get in the way of the weld path that the torch needs to take. In picture number 8 we can see an example of a customer’s fixturing and clamping arrangement.

Second, as the nozzle of the torch will suffer a build-up of weld spatter over time there is a reamer fitted to the tip clean which will move up inside the nozzle to clean the tip of this build-up. Likewise, the removed spatter will fall into a removable collection dish mounted under the reamer. Lastly, the robot moves the torch over to the parting agent spray system. Then, it will spray a parting agent up into the newly reamed nozzle.

6. Robot Cell Guarding

The cell will need some form of guarding. Thus, this form of a room or enclosure will make sure that nobody is present whilst the robot is working in automatic. However, the guarding or room enclosure will have any access points protected by a two-channel safety system that is integrated into the safety panel.

Guarding Protect Staffs

The guarding will also protect against the flash from the welding process.  In addition, there are a number of two-channel booth access safety systems that can be used from a simple two-channel safety switch connected to the safety relays on the safety panel. In this case, the access to the cell via the door does not prevent the person from entering but will automatically stop the robot if someone does when the robot is running in automatic.

7. Welding Cell Safety Panel

To control the complete cell a safety panel with cell control pushbuttons will be installed which is electrically connected to the robot controller. This panel will include the safety relays for the two safety circuits for both the robot and positioner. One circuit will be for the Estops, these will stop the robot in all modes, the other will be for the cell access and this will stop the robot and positioner whenever the robot is in Auto mode if the access door to the cell is opened.

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