Main components of a complete arc welding robot system

The welding equipment​

The welding equipment used by an industrial arc welding robot is different from the equipment used for manual welding. The duty cycle of a welding robot is much higher, meaning that the robot can operate continuously for longer periods of time without overheating or requiring a rest period. As a result, the quality of the welding equipment used by a welding robot must be higher to withstand the increased demands placed on it. This means that the welding equipment used by a welding robot is designed to be more durable, reliable, and capable of producing consistent, high-quality welds over an extended period of time.​

The integration of a power source with the robot controller is crucial to get the maximum output of the robot system. The faster the communication happens, the more features are available on the market to push the limits of the arc welding process. Today, almost every robot has a digital interface, but Panasonic has the “fusion” platform where one CPU is controlling the robot arm, the wire feeder, and the many available waveforms. The communication speed of the fusion platform is 250 times faster than any other digital interface. This allows for faster and more accurate control of the welding process, resulting in higher quality welds and increased productivity.​

It is important to have all the welding parameters defined in a unique way into the robot program. This allows for greater control and consistency in the welding process, resulting in higher quality welds. The integration of the power source with the robot controller is crucial in achieving this, as it allows for faster and more accurate communication between the two systems. This, in turn, enables the use of more advanced features and technologies to push the limits of the arc welding process. With the maximum freedom to act, the robot can adjust its movements and welding parameters in real-time to achieve the best possible results.​​

Wire feed motor​

​Feeding the wire at a constant speed is important for achieving the best welding quality. The use of a servo motor controlled wire feeder can provide better constant wire feeding with less influence from the resistance in the liner. This allows for greater control over the welding process and the ability to use all wire diameters in all different materials. Real-time resistance control is also important, as it allows for the detection of any changes in resistance and the ability to make adjustments in real-time to maintain consistent wire feeding. This results in a smoother and more consistent weld, which can improve the quality of the finished product​.​

The robot welding torch​

The robot welding torch is an important component of the welding process for several reasons. It must be robust to withstand the high temperatures and rough conditions of the welding process. The torch can be either water or air cooled, depending on the specific requirements of the application. The feeding of the wire and shielding gas must be precise to ensure consistent and high-quality welds. In the case of TIG welding, the torch must also be able to hold the electrode securely. The torch must be precise, with a consistent tool center point (TCP) to ensure accurate and repeatable welds. Quick exchange and easy cleaning of the torch are also important factors to consider, as they can help to reduce downtime and improve the overall efficiency of the welding process​

A calibrated welding torch is indispensable for high mix low volume production. When you have many programs available in the robot, all those programs must remain perfect after exchanging the robot torch. This is because a calibrated torch ensures that the tool center point (TCP) remains consistent, allowing for accurate and repeatable welds. This is particularly important in high mix low volume production, where there is a need for flexibility and adaptability in the manufacturing process. It is important to check with your supplier before making a decision to ensure that the torch is calibrated and suitable for your needs​.

Automatic torch exchange​

Automatic torch exchange is important in several scenarios. For example, when changing between MIG and TIG welding processes, an automatic torch exchange system can quickly and efficiently switch between the two types of torches. This can save time and improve productivity in a high mix low volume production environment. Additionally, in situations where unmanned production is taking place and nobody is available to change the contact tip, an automatic torch exchange system can ensure that the welding process continues uninterrupted. Special torches designed to improve reachability in the welding jig can also be quickly and easily exchanged using an automatic torch exchange system. It is important to check with your supplier before making a decision to ensure that the automatic torch exchange system is suitable for your needs.​

Automatic TIG electrode changer​

​An automatic TIG electrode changer can be important for maintaining the quality of TIG welds. The sharpness of the TIG electrode is crucial for achieving the best welding quality, and regular sharpening or replacing the electrode with a sharpened one can help ensure a perfect TIG weld. In unmanned production, this feature can make a significant difference, as it allows for the electrode to be changed automatically without the need for human intervention. This can help maintain consistent welding quality and reduce downtime​.

Mechanical automatic cleaner for welding torches​

A mechanical automatic cleaner for welding torches works by using a cleaning reamer to remove any debris or buildup from the gas nozzle of the welding torch. The welding torch is moved to the cleaning position and the bottom edge of the gas nozzle is positioned above the reamer casing. The cleaning motor is then moved into position and the cleaning reamer is inserted into the gas nozzle to clean it​

The advantages of using a mechanical automatic cleaner for welding torches include improved efficiency and reduced downtime, as the cleaning process can be performed quickly and easily without the need for manual intervention. This can help to maintain consistent welding quality and improve the overall productivity of the welding process.​

However, there are also some risks associated with using a mechanical automatic cleaner for welding torches. If the cleaning reamer is not properly inserted into the gas nozzle, it can cause damage to the welding torch. Additionally, if the cleaning motor is not properly positioned or secured, it can also cause damage to the welding torch. It is important to follow the manufacturer’s instructions and perform regular maintenance on the cleaning system to minimize these risks​.

Some examples of systems with different kind of positioners and tracks

Multiple robot systems and integrated logistic solutions​

Incorporating multiple robots in one system or extending the system with logistic solutions around the robot system can improve the output. This is because the robots can work together to complete tasks more efficiently and quickly. Additionally, the flexibility of the system will increase if welding jigs are replaced by flexible robots. This means that the system can adapt to changes in production more easily and quickly. The output per meter footprint of the floor space will also increase, as the system can produce more in the same amount of space. However, this level of automation needs to be considered as a company strategy and fully supported by everyone involved. It is important to be aware that the requested investment will be higher and that more skilled people will be needed to make a success out of such an investment.

Multiple robot systems in general​

For arc welding, we see the following main reasons for switching to multirobot systems:​

• More melts down on a smaller area and a smaller area​
• Even heat distribution / deformation of the product to be welded​
• Shorter cycle time​
• Fixed costs are shared (e.g. welding jigs)​

​The main disadvantages are:​

• More complex programming​
• Higher risk of collisions​
• Higher risk of downtime​​

Multiple robot systems in general – how do the robots communicate​

​Hand-shake​
With the handshake system, both robots are equal and communicate with each other via a "handshake".​

• As soon as they threaten to enter an equal zone (risk of collision).​
• As soon as the welding jig has to be turned, e.g.​
• At the end of a program with workstation enable​

Handling of the product and continued welding is not possible with the hand-shake system.​

Leader-Follower​

• ​Perfectly synchronized. ​
• The cycle time very crucial is​
• The product already welded should be rotated​
• The distribution of the heat input is very important.​

What to be known?

IWE/IWS/IWT

• Is it always a good idea to connect a power source for manual welding to a robot system? Please explain why yes or no?
• How can we let the robot detect pollution of the welding wire liner?

IWE/IWT only

• What is the difference between a digital interface between robot controller and power source and the fusion platform?
• Why is a fusion platform also important for full treacability?
• Why is a servo controlled wire feeder an advantage?
• Why are calibrated welding torches important in high mix/low volume applications?
• Give me 2 reasons to consider an automatic torch exchange system
• Give me the reason to consider an automatic TIG electrode changer
• What’s the goal of investing in an automatic cleaner for welding torches on arc welding robot systems?
• Give me 4 reasons to install more than one robot in a robot system. Give me also 3 reasons not to do.
• When we have multiple robot arms in one system, what are the 2 ways of communication between them?