Understanding the Basics: How Does Robotic Welding Work?
Automated Robotic Welding Services
Automated robotic welding services have significantly transformed the manufacturing industry, offering enhanced precision, efficiency, and consistency. Robotic arc welding is a highly efficient and precise method of joining metal components. It offers numerous benefits, such as increased productivity, improved weld quality, and cost savings.
This guide will detail each step involved in this robotic welding process, from programming the robot and preparing the workpiece, to initiating the arc, controlling the motion, and conducting quality inspections. By understanding and implementing these steps, you can maximize the benefits and importance of automated robotic welding services in your manufacturing operations.
Welding Robot Capabilities
Alliance Fabrication & Manufacturing has multiple cells equipped with Fanuc Arc Mate Robots, Fronius TPSi 500 power supplies with CMT, dual workstations with H - Type Positioner (rotary axis), and Bluco Modular Fixturing System. These capabilities allow us to produce complex weldments in a variety of sizes.
Our Fanuc Arc Mate robots are high–speed units capable of welding large format sizes. Programming can be done both on the teach pendant and offline software.
The Robotic Welding Process
1. Programming The Robotic Welding Equipment
The first step involves carefully planning the weld sequence to manage heat dissipation and control the thermal movement of the components. Once the welding sequence plan has been created, it is digitized by importing the solid model of the part and welding fixture. The programming path is then applied based on the welding sequence, and any part or fixture collisions are addressed as needed. After the programming has been applied and all collision avoidance issues are addressed, our fixture design becomes finalized. The tooling can then be built based on the successful completion of the welding simulation.
Arc welding parameters are developed specifically for each application and stored as jobs in the power source. The welding jobs are incorporated into the tool path instructions during the programming process. Each weld segment has the appropriate welding job linked to it.
Benefits:
- Increased precision and repeatability
- Reduced welding defects
- Improved deposition rates
- Verification of fixturing viability
- Optimal thermal input
2. Robotic Welding Equipment Preparation
Before initiating the welding process, it is crucial to prepare the workpiece properly. This involves cleaning the metal surfaces to remove any dirt, oil, or rust that could negatively impact the quality of the weld. Additionally, the workpiece must be securely positioned in the welding fixture to ensure stability during welding.
Benefits:
- Optimized joint fit-up
- Ideal joint penetration
- Reduced welding defects
3. Robotic Arc Initiation
Once the robotic welding equipment is programmed and the workpiece is prepared, the next step is to initiate the arc. This is achieved by bringing the welding torch close to the workpiece and initiating the arc start sequence. There is a gas preflow of inert gas to protect the arc ignition, with the actual arc ignition starting about .2s after the gas preflow. The arc ignition generates intense amperage to join base and filler metal together, thus mechanically joining the pieces together. The arc continues as the robot guides the torch to its end destination, where arc end sequence slowly stops the wire feeding, taking care to fill the crater in and then giving it an additional .3s of gas after the arc extinguishes to allow the crater to cool with getting any contamination in the weld pools.
Benefits:
- Quick and efficient start of the welding process
- Clean starts and stops with adequate crater fill to prevent cracking
- Minimal distortion of the workpiece
4. Controlled Motion
During the robotic welding process, the robot carefully controls its motion to follow the programmed weld path. This is achieved by utilizing various types of robotic motion, such as linear, circular, or oscillating movements. The robot's ability to accurately control its motion ensures consistent and high-quality welds.
Benefits:
- Improved weld accuracy and repeatability
- Reduced operator fatigue
- Increased welding speed
5. Monitoring and Adjustments
The intelligent robotic arc welding systems constantly monitor, measure, and correct the arc voltage and amperage as it moves. It makes corrections to the weld pool in real time to ensure optimal droplet detachment, which provides optimal wire deposition rates and faster travel speeds.
6. Quality Inspection
Alliance Fabrication and Manufacturing partners with some of the most reputable suppliers, making quality & customer service paramount. We believe that quality parts are a competitive advantage.
Quality Assurance or QA is a detail-oriented process of checks and balances used in the fabrication and manufacturing space to ensure the customer receives the highest quality parts and components.
Benefits:
- Enhanced weld integrity and strength
- Early detection of welding defects
- Compliance with industry standards and regulations
Robotic Welding Services at Alliance Fabrication & Manufacturing
Robotic welding, with its precise control, repeatability, and efficiency, has revolutionized the manufacturing industry, enabling the production of high-quality welded components at a faster pace and with greater consistency than traditional welding methods. Alliance Fabrication & Manufacturing offers various intelligent fabrication and manufacturing services to many industries and sectors.
Integrating state-of-the-art software and technology, years of experience, and industry knowledge, backed by data-driven results and dedicated staff, Alliance Fabrication & Manufacturing provides product performance and repeatability.
Contact us today at 219.319.1606!
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