You are on page 1of 6

Robot welding is the use of mechanized programmable tools (robots), which completely automate a welding process by both performing

the weld and handling the part. Processes such as gas metal arc welding, while often automated, are not necessarily equivalent to robot welding, since a human operator sometimes prepares the materials to be welded. Robot welding is commonly used for resistance spot welding and arc welding in high production applications, such as the automotive industry. Robot welding is a relatively new application of robotics, even though robots were first introduced into US industry during the 1960s. The use of robots in welding did not take off until the 1980s, when the automotive industry began using robots extensively for spot welding. Since then, both the number of robots used in industry and the number of their applications has grown greatly. In 2005, more than 120,000 robots were in use in North American industry, about half of them for welding.[1] Growth is primarily limited by high equipment costs, and the resulting restriction to high-production applications. Robot arc welding has begun growing quickly just recently, and already it commands about 20% of industrial robot applications. The major components of arc welding robots are the manipulator or the mechanical unit and the controller, which acts as the robot's "brain". The manipulator is what makes the robot move, and the design of these systems can be categorized into several common types, such as the SCARA robot and cartesian coordinate robot, which use different coordinate systems to direct the arms of the machine. The robot may weld a pre-programmed position, be guided by machine vision, or by a combination of the two methods. [2] The technology of signature image processing has been developed since the late 1990s for analyzing electrical data in real time collected from automated, robotic welding, thus enabling the optimization of welds.

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

Consistent Quality Welds Reduction of Production Costs Better Return On Investment (ROI) Repeatability Faster Cycle Rates Higher Deposit Rates than SMAW Longer Welds Without Stopping High Quality Welds Less Operator Skill Required Minimal Post Weld Cleaning Increase Return On Investment (ROI) High Quality Welds Low Distortion Variable Precise Controls Spatter-free Consistent Quality Welds Reduction of Costs More Movement Flexibility Repeatability Increase the Return On Investment (ROI) Consistent Quality Welds Greater Cycle Speed Safer Workplace Repeatability Reduction of Costs

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 Contact AMC engineering for robotic welding consulting or planning a robotic production line. Hire our consultant to act as your welding specialist.

The advantages to robot welding:

Faster welding cycle times No breaks in production Better quality weld product Less wasted material Consistent weld seam Removes workers from hazardous work environments More precision, flexibility to reach hard-to-reach spots Saving money through speed, quality production and fewer labor costs

Robot Welding is still the most common application for robotic automation with the automotive OEM's, tier1 and tier2 suppliers being the largest single market segment for this process. However, the application has long since been adopted by general industry, as the technology has become more cost effective.

Robot welding is most commonly associated with MIG (Metal Inert Gas) welding or resistance spot welding. However, other methods of robot welding are frequent used, including TIG (Tungsten Inert Gas), Plasma, TIG Filler (TIG Welding with Filler Rod) and Laser Welding. It is estimated that the world wide population of operational industrial robots now exceeds 1,000,000 robots, with over half of that number being used for robot welding.

Robot welding was seriously introduced to industry in the 1970's and since then the number of installations has increased significantly year on year. Robot welding offers so many more benefits over manual welding, i.e. improved takt time, quality, repeatability, access to difficult weld positions, data collection and reductions in health and safety risks.

Market demand and expectations has pushed the major robot manufacturers to continuously develop their robot welding products to new levels of effectiveness even though buying prices have continued to fall. In the last five years the application of more powerful CPU processors and the gradual move from analogue to full digital control has transformed the performance and functionality of robot welding solutions. Offerings such as the Panasonic TAWERS welding robot set the standard for robot welding solutions for the automotive sector and general industry as it offers full integrated digital control of the weld set parameters; wire feed rates and robot motion, sampling the feedback and optimising the settings 50 times per second. This level of control by the Panasonic TAWERS welding robot delivers outstanding deposition rates and fast arc start/finish response times without compromising the integrity and appearance of the weld.

http://www.youtube.com/watch?v=CjO7BPHjjMU&feature=related

You might also like