How to successfully implement a robot for welding processes

Once you’ve decided to acquire a robot for welding processes, it’s important to review certain points to ensure successful automation. Here, we’ll show you several recommendations to follow so that your investment can bring the promised results.

Recommendations for implementing a robot for welding processes

Some of the main objectives of welding process automation are to provide increased productivity, improve the quality standards of welded products, and significantly reduce production times.; which translates into a decrease in manufacturing costs. The initial investment in welding process automation can be high in principle, but proper systematisation of processes and stable workflows are key to a quicker than expected return on investment. Any type of company, regardless of size and production volumes, that experiences problems in its welding processes, a shortage of qualified welders, or excessive overtime due to cleaning and final finishing; are prime candidates for the implementation of welding robots. Robots can perform practically any type of welding and adapt to an endless number of projects, they show great versatility and present a wide variety of advantages. Here we show recommendations for implementing a welding robot and obtaining the best results.

• Design and program all welding process parameters.

Welding parameters such as amperage, travel speed, electrode pressure, wire feed speed, and others, must be designed with care. It is necessary to know exactly, according to the work to be performed, the required filler material, its size and characteristics, which is one of the most important tasks. The productivity and quality of the weld largely depend on this choice. Both the filler material and the welding parameters to be used are determined based on the type of material to be welded and the dimensions of the component.

Another factor that needs to be designed and programmed is the clamping table for the parts to be welded and the characteristics of the joints to be welded. Poor clamping where components can move incorrectly or excessive opening of the joint to be welded leads to serious problems with penetration and porosity, which is unacceptable in welding.

Determining the correct welding parameters often requires time, but once found, they guarantee optimal results, sometimes Robot manufacturers for welding processes recommend parameters to use according to the filler material., This could serve as a guide, but you shouldn't rely on this alone; the best approach is to conduct pilot tests to find the appropriate welding parameters and filler material for each particular project.

• Establish and maintain TCP.

One of the fundamental variables that must be established and maintained is the tool centre point, known by its English acronym as the TCP (Tool Centre Point), for the Robotic welding process. This ensures the correct operational position of the equipment and is the most important reference point for programming the welding equipment's motion paths. In some cases, depending on the technology available, the robot's program may automatically correct the TCP; however, in many cases, it must be set and corrected using other procedures. It is necessary to design a schedule for TCP verification, as when equipment is outside the acceptable TCP range, problems arise with motion paths, decreasing welding productivity and quality.

• Programme the robot's movement path for the welding process.

It is very important to build and program the welding robot's movement trajectory. This trajectory must take into account the material to be welded, the filler material, the welding process, the welding angle, the entry and exit speed, among others. Furthermore, it must ensure that there are no collisions of any kind, especially collisions of the welding gun with the component, as this increases its wear, decreasing its lifespan, and in the case of major collisions, the TCP could be deviated. There are automated welding equipment that contains collision protection systems and shutdown systems in case of accidents; these are highly recommended.

It is better to avoid complex trajectories; the simplification of tasks leads to better results. The correct penetration of the weld and the stability of the electric arc length must be guaranteed, with the aim of certifying the weld quality. Many machines include systems that help establish the robot's initial movement trajectories, which is a significant advantage.

• Consider the gun, accessories and consumables.

The welding gun and accessories such as contact tips, gas nozzles, and consumables have a significant impact on robotic performance for welding processes., The correct choice of these increases cell efficiency as it can reduce downtime.. It is important to consider that the duty cycles of the welding equipment in these robotic cells are much higher than for manual or semi-automatic welding, which warrants that the torches, accessories and consumables be chosen for these prolonged service times and for high temperatures. This helps to reduce wear and increase the service life of the tooling. The installation of the torch, accessories and consumables must be appropriate to avoid wear and premature failures in them. The service life of the torch also depends on the movement path, and it is best to avoid collisions to reduce the failures it may present.

• Look after and maintain your welding equipment.

The proper installation of a robot for welding processes is paramount. It is recommended that this be carried out by experts, and it is necessary to have a specialised team of qualified programmers. Consideration must be given to the correct installation of the wire or filler material feeding systems, the shielding gas in case the welding process requires it, and the clamping system or tools for the workpieces. The earth connection cables or other cables, such as the wire feed and gun cables, are generally long to facilitate the mobility of the welding equipment or gun to some extent; however, an excessive length of these cables and a poor installation of the protective covering lead to their excessive wear. Correct installation should be performed, using appropriate lengths that allow the robot to move without setbacks, and avoiding cable splices in connections.

Where possible, it is advised, within the scope of the movement trajectory, to simplify the working axes of the welding equipment and reduce excessive flexing of the torch cable, as this increases the lifespan of the components. Finally, it is important to remember that the cell requires a trained, attentive, and expert operator in the welding process; the equipment needs highly prepared personnel to command it.

The versatility and variety shown by commercial robot houses for welding processes are enormous; there are machines for all kinds of requirements, from medium to small. companies can have access to automated welding equipment at relatively low costs, which exponentially favour their welding projects, transforming them into much more competitive and efficient companies when responding to new market demands. However, the need for continuous planning and monitoring cannot be overlooked, once welding robots have been installed, as this would ensure the full benefit of the investment.