The application of welding robots not only combines the advantages of high and stable efficiency, but also possesses excellent flexibility, ensuring stable operations even in complex environments.
A complete welding robot system includes the robot body, robot welding equipment, welding positioner, control system, and other auxiliary equipment.
How is the stability and welding quality of welding robots? According to welding experts I consulted, the key factor affecting the quality of robot welding is indeed the technical issue of the robot operator.
There is a yellow cover layer on the surface of the weld after manual welding, but using a welding robot can avoid such issues and ensure welding quality.
First, we should know that this yellow substance is actually impurities in the welding wire and welding base material, mainly caused by the high-temperature oxidation of silicon and manganese elements during the welding process, which reacts chemically with the CO2 gas in the shield and decomposes to form silicon oxide and manganese oxide. Oxides are somewhat similar to the slag formed during manual electrode welding.
Although these phenomena are also produced by using welding robots, these oxides do not adversely affect the welding quality except for a slight appearance, and can be easily removed with a brush.
There are some silicon and manganese elements in the metal elements of the solder base material, and this phenomenon is objectively present.
If you want to reduce these oxides, you can use wires with less silicon and manganese elements and use less carbon dioxide protective gas. When using mixed gas, there will be less oxide welding and many fewer yellow spots.
There are many factors that affect the welding quality, among which the larger ones are the welding defects and the selection of welding parameters.
Welders who have been engaged in welding work for a short time cannot handle welding problems well, leading to internal slag inclusion, porosity, undercut, and welding nodules and other welding defects.
In the selection of welding process parameters, each welder will adjust the welding current, welding voltage, type and polarity of the welding power source, welding speed, and diameter and extension length of the welding wire according to their actual experience.
Choosing the wrong welding parameters due to insufficient experience may lead to a decline in welding quality.
Many welders, while paying much attention to the results of nondestructive testing, often neglect the appearance quality of the weld, leading to unqualified weld appearance and rework, thereby reducing labor productivity.
The advantage of using welding robots lies in their stable operation, while ensuring the welding quality meets or exceeds expectations. The adjustment of welding process parameters with robots is straightforward and only requires direct setting.
Moreover, robots have built-in formulas to automatically adjust the current and voltage. During robotic welding, the welding parameters for each weld are constant, minimizing the influence of human factors on weld quality and reducing the technical demands on robot operators.
To make the operation of welding robots more flexible and intelligent, we recommend users equip them with a seam tracking system. This system automatically detects and adjusts the position of the welding torch during the welding process, ensuring it always follows the welding position.
It maintains a constant distance between the torch and the workpiece, thereby ensuring welding quality, improving welding efficiency, and reducing labor intensity.
This system can solve welding quality issues caused by heat distortion and inconsistencies in the workpiece. Additionally, it can liberate welders from harsh environments, reducing the risk of physical injuries.