Step-by-Step Guide to Operating and Mastering Arc Welding Robots

Step-by-Step Guide to Operating and Mastering Arc Welding Robots

Arc welding robots may be unfamiliar to many, including myself, prior to this! Don’t mistake this robot name for a children’s toy or a Transformer-like toy!

In fact, an arc welding robot is a kind of industrial robot.

The primary function of an arc welding robot is to perform automatic arc welding, which means using a robot for automated welding, replacing traditional manual welding by welders.

If you have studied arc welding robots, you would know that its principle is quite similar to that of spot welding robots.

As early as the mid-1980s, China had invented the first generation of arc welding robots for industrial use. It consists of five main parts: a control panel, the robot itself, and an automatic wire feeding device.

Under the precise calculation and control of a computer, it performs continuous trace control and point control. Compared to the operation of ordinary welders, arc welding robots are more efficient and faster, and most importantly, the welding process is more accurate.

The basic components of an arc welding robot system include the robot body, control system, teaching device, welding power source, welding torch, welding fixture, and safety protection facilities.

Of course, the system components can be selectively expanded based on different welding methods and specific welding process requirements of the workpiece to be welded, such as wire feeder, torch cleaning and wire cutting device, cooling water tank, flux delivery and recovery device (when SAW), mobile device, welding positioner, sensors, dust removal device, and so on.

The main operation modes of arc welding robots are divided into two types, both of which can carry out long-term welding, thus effectively ensuring high efficiency and quality of the operation.

Compared to other welding methods, the stability of this mode is unparalleled. In recent years, with the continuous development and expansion of technology, arc welding robots have been constantly evolving towards digitization.

With the inclusion of arc welding robots, the efficiency of the entire electric welding connection process and the technical requirements of the products have been improved, and this technology will be increasingly used by more industries, gradually forming unmanned factory operations.

How should we operate after purchasing an arc welding robot? We’ve never operated it before, are there any safety concerns initially? I’ll now discuss the safety operation standards for arc welding robots, providing a clear understanding of correct operation to avoid injuries.

Prior to production, we must inspect whether the equipment is in good condition, and then check the safety of the site where the arc welding robot is to be used. If everything seems normal after the inspection, we can switch on the main power. Once the main power switch is on, we need to check whether the indicators for current and voltage are functioning properly.

If they display normally, we can then open the valve of the shielding gas cylinder and check its status. We also need to open the valve of the air source and check its normality. If everything checks out, we can commence work.

Key Technologies of Arc Welding Robots

1. Optimized integration of arc welding robot systems:

The arc welding robot implements alternating current servo-drive technology, coupled with high-precision, high-rigidity RV speed reducers and harmonic drives. This ensures excellent low-speed stability and high-speed dynamic response, enabling maintenance-free operation.

2. Coordinated control technology:

This allows for the synchronized movement of multiple robots and positioners, maintaining the relative posture of the welding torch and workpiece to meet welding process requirements, while also avoiding collision between the torch and workpiece.

3. Precise weld seam tracking technology:

This combines the advantages of offline operation of laser and vision sensors. The laser sensor is used for seam tracking during the welding process, enhancing the robot’s flexibility and adaptability when welding complex workpieces. The vision sensor is used offline to observe the residual deviation of seam tracking.

Based on deviation statistics, compensation data is obtained and used to correct the robot’s movement trajectory, ensuring optimal welding quality under various conditions.

Upon completion of the arc welding robot’s operation, we first need to close the gas valve, then the gas cylinder, followed by the main switch, all in that order. After shutdown, the machine should be cleaned and tidied, followed by another inspection to ensure that the arc welding robot has not been damaged during production.

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Shane
Author

Shane

Founder of MachineMFG

As the founder of MachineMFG, I have dedicated over a decade of my career to the metalworking industry. My extensive experience has allowed me to become an expert in the fields of sheet metal fabrication, machining, mechanical engineering, and machine tools for metals. I am constantly thinking, reading, and writing about these subjects, constantly striving to stay at the forefront of my field. Let my knowledge and expertise be an asset to your business.

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