Advice on Robotic Welding Systems

[AZDEN]

I have a high volume production welding project that I think will be well suited for a robotics application, however I have no experience in this at all. The most complicated component contains multiple compound angles. The part is not all that big at 24" x 18" x 16". What should I look for/look out for in choosing a system? Any other recommedations will be greatly appreciated.

 

[tygerdawg]

go look at

http://www.fanucrobotics.com

and

http://www.motoman.com

, just to list two robot vendors. Also ABB, Panaonic, Daihen, Kawasaki, KUKA, I'm sure that there are others. They supply complete welding systems with positioners, etc. Give them your name & number and the salesmen will never stop calling.

Other sources of general info:

http://www.roboticsonline.com

http://www.sme.org

Lincoln Electric

You will need to do more specification: path accuracy required, throughput, material, whether to teach paths manually or create them with CAD offline, quantity of different parts, positioners (turn- or tilt/turn) required for your "high volume", material into cell and out of cell, fixturing, etc. ad nauseum.

TygerDawg

 

[28021973]

http://www.robotsystems.co.uk/

Ask yourself the question, do you want a robot from a manufacturer that is capable of making there robot weld.

!! Or do you want a robot that only specialises in welding.

There is a massive difference in there abilitites.

I currently work with Fanuc, ABB and panasonic equipment, and I have have had the experience of working for comau and igm in the past.

Companies such as igm/cloos are far more advanced in the welding field than any other robot manufacturer. They provide turnkey systems for any application, and they never walk away from a challenge.

Check out there websites, see what they do, you will see the likes of igm/cloos show pictures and applications of nothing but welding and cutting.

 

[Barry1961]

Any brand welding robot can handle the accuracy. Some robots have smaller knuckles near end of arm that may help getting into tight places. Pick one that you feel will give good support in your area, for the robot and welder.

If this is the first welding robot in the building you are about to learn a lot about tolerance stack up and fixturing. Unless you can do a weave or have a groove big enough for TAST you need to hold your seam position within one wire width. Getting your quality control to the point where you can use a welding robot is something to be proud of.

Some common problems I have run into doing installs are..

1. People will not worry about their parts being within tolerance and decide to buy a robot to "see how it does" first. The thought is that the robot failing time and again will force them to improve part quality.

2. The fixturing cost twice what the robot does. Be glad it didn't cost four times as much.

3. Wire flipping and curving as it comes out of torch. I have seen the wire vary +/- .125" with a 1.5" stickout. You can get straighteners and "no cast" wire that will help.

4. You will crash the robot and bend the torch a few times. Be prepared with a tip check, re-mastering setup and spare torches.

5. Don't re-teach points with a bent torch.

6. Try to locate the seams in the fixture if possible instead of the outside edges. It may be a two step process.

7. I have done custom robots that assembly the parts before welding and measure the parts when they are picked up. This allows the weld path to be offset to match each part. You can also do this on the cheap with some position feedback on you fixture if lucky.

I would need to know more about your app to give any detail.

Barry1961

 

[28021973]

You will want ease of use, good feedback etc, automatic corrections etc.

Igm robots have.....

1. K5 teach pendant - windows style teach pendant.
2. Instant feedback to TP with welding parameters in real time, you dont need to look at the weld set.
3. Automatic tcp correction.
4. 720 deg axis 6, which the hose pack goes through the centre of axis 6, the only robot on the market that does this..! Can a abb, fanuc, kuka rotate 720 with its hose pack on - NO.
5. You do not have to change the robot speed in teach mode to weld unlike some robots, not all though.
6. Arc seam sensing and touch sensing and laser camera very easy to use. (selectable menu's) no complex software programming.
7. Tandem wire welding with torch exchange no problem.
8. Rack and pinion removed from gantry systems, uses a laser to guide to gantry.