The Definitive Guide to Robotic Welding Torches 

Guide to robotic welding torches

Robotic welding 

Guide to robotic welding

Robotic Arc Welding 

Information on Robotic Arc Welding

Complete Guide to Robotic Welding 

Complete guide to robotic welding from fairlawn tool inc

Anatomy of a robot-based welding system 

Information on Robotic welding process

Welding Automation and Robotics

Robot welding is the use of mechanized programmable tools, which completely automate a welding process by both performing the weld and handling the part.

Commonly used for resistance spot welding and arc welding in high production applications, such as the automotive industry.

Types of welding robotics

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.

Robotic Welding Processes

1. Arc Welding: an electric arc between an electrode and metal base produces an intense heat to melt and intermix two parts. Arc welding is used for applications calling for high accuracy and repeatability.
    
2. Resistance Welding: a current is passed between two metal pieces of metal, a pool is formed by the resulting heat, and the two pieces are joined together. Resistance welding is the most economical form of robotic welding and is best for heat-treating projects.
    
3. Spot Welding: a type of resistance welding, spot welding joins thin metals that resist electrical currents. It’s typically used in the automotive industry to join sheet metal frames together.
    
4. TIG Welding: a high-quality process where an arc is formed between a non-consumable tungsten electrode and the metal part. Also known as Gas Tungsten Arc Welding (GTAW), TIG welding is used when precision is of the utmost importance.
    
5. MIG Welding: a high deposition rate process that involves feeding a wire continuously toward the heated weld tip. Also known as Gas Metal Arc Welding (GMAW), it is best for applications where system simplicity and speed are desirable.
    
6. Laser Welding: a laser generator delivers via a fiber optic cable a laser light through a robotic cutting head to weld pieces together. Laser welding, including remote laser welding for hard to reach weld locations, is often used in high volume applications that require high accuracy, such as the automotive sector or in the medical or jewelry industries.
    
7. Plasma Welding: ionized gas passes through a copper nozzle to produce extremely high temperatures. Plasma welding is used when flexibility is required, as velocity and temperatures can be easily adjusted.

computer-aided design (CAD): Computer software programs that typically use vector lines to produce a mechanical type drawing

computer-aided manufacturing (CAM): Computer software programs used to aid in the automated manufacturing of parts.

A manual joining process is one that is completely performed by hand.

A semiautomatic joining process is one in which the filler metal is fed into the weld automatically.

An automatic joining process is a dedicated process (designed to do only one type of welding on a specific part) that does not require adjustments to be made by the operator during the actual welding cycle

A machine joining process is one in which the joining is performed by equipment requiring the welding operator to observe the progress of the weld and make adjustments as required.

An industrial robot is a reprogrammable, multifunctional manipulator designed to move material, parts, tools, or specialized devices through variable programmed motions for the performance of a variety of tasks. Industrial robots are primarily powered by electric stepping motors, hydraulics, or pneumatics and are controlled by a program.

Sensor: A transducer whose input is a physical phenomenon and whose output is a quantitative measure of the physical phenomenon. Some units have sensors that track the joint even if it varies from the programmed path.

Safety

The following precautions are recommended for the use of automatic welding equipment and robots:

● All personnel should be instructed in the safe operation of the robot.

● All personnel should be instructed in the location of an emergency power shutoff.  

● The work area should be restricted to authorized persons only.

● The work area should have fences, gates, or other restrictions to prevent access by unauthorized personnel.

● Sensors should be mounted around the floor and work area to stop all movement when unauthorized personnel are detected in the work area during the operation.

● The arc welding light should be screened from other work areas.

● A breakaway tool holder should be used in case of accidental collision with the part

● A signal should sound or flash before the robot starts moving.