Introduction to How Robotic Welding System Works
Many industries are now adopting automated processes because they are cost-effective and they increase efficiency in workplaces. The metalwork industry is at the forefront in properly utilizing robotic welding and automation. Robotic welding enhances safety at work while it also improves accuracy and delivery.
It also reduces the time needed to complete a project. These are some of the pros that make automated welding preferable to manual welding.
It is also beneficial to various industries because it speeds up the welding process and offers fine finishes. To help you understand better how robotic Weldsaver works, read this detailed article about robotic welding.
Different Welding Process
|Submerged Arc Welding(SAW)||Ultrasonic||Explosive||Thermite|
The first 4 are the slang terms used for welding.
Stick welding is the slang name of Shielded Metal Arc Welding(SMAW). The rod used for welding looks like a stick. The Stick is the major power source that generates amperage for creating the arc. In such welding below are the materials used:
- Rod or electrode
- Metal with a flex coating(electrode)
It is cheap and works perfectly on most of the metals. It also always welding thick materials. SMAW is the most basic yet most used welding technique.
MIG is the full form of Metal Insert Gas otherwise known as “GAS Metal Arc Welding”(GMAW). Note the gas used in this technique may vary. The good name of MIG is Wire Wheel Welding. In this technique, a solid wire is fed to weld a joint. The solid feed is connected to a constant voltage power source that makes the arc by melting.
However, before the arc is created a shielding gas is used to feed into the system.MIG guns are used to perform MIG welding. MIG gun includes the wire, electricity, shielding gases at the same time.
MIG guns are having a trigger, once triggered, it starts the metal welding process. This is a semi-automatic process. This type of welding is used in large scale factories where high productivity is needed. It is easy to operate but needs the experience to set up.
Flux Cored Arc Welding(FCAW)
Flux Cored Arc Welding(FCAW) is a little different as they use different electrode and filler wire. The electrode is a hollow tube having flux in the centre. It does not use an external shielding gas. There are two types of electrodes for FCAW. They are as follows:
- Dual Shielding
Self-shielding is an electrode that can work without shielding gas. MIG can not be operated in windy conditions hence FCAW -Self-shielding solves the problem.
Dual shielding needs gas to operate and work properly. It is used in large to very large welding scenario like- shipward or anywhere where a lot of welding and lots of metal deposit is required.
TIG – Gas Tungsten Arc Welding(GTAW)
TIG is the short form of “Tungsten Inert Gas”, however, note that the original name is Gas Tungsten Arc Welding(GTAW). long back it was also known as “Heli Arc”. GTAW needs constant power. It uses a torch having one piece of tungsten to produce an arc. The torch protects the weld area from the air. TIG torches 10000-degree Farenhite during welding.
Initially, TIG welds and the filler metal is then put into the joint. Fillers are mainly wires and lengths can be adjusted as per need. The gas used is Argon that can work well with 90% of the metal.
How Robotic Welding System Works
Automation in industrial processes requires amending when using robots. The same goes for welding. The tools and equipment used in robotic welding are not the same as those used in manual welding. You can’t use programs on people as you do with robots.
In robotic welding, a robot arm is used to move in three dimensions for rectilinear types. The filler wire to the robot using a wire feeder should be required for the welding job. To commence with the welding process, the arm needs to have a high-heat torch at the end for melting the metal. It also requires a properly set up welding water saver for cooling. Operators are kept safe from molten metal that has temperatures that reach thousands of degrees.
Robots can’t work entirely by themselves while welding. Operators need to work at a distance to monitor the welding process. Before an operator is allowed to operate robotic welding machines, he needs to hold certification from the American Welding Society – AWS. This society doesn’t only certify manual welders but also robotic welding arm operators.
A teach locket is used by the operators when programming the controller. The teach pendant is a device used to set new programs, change parameters for the process, and move the robotic arm. The buttons on the operation box allow the operator to start the welding process.
Metal is heated at a very high temperature and melts using the tool in the robotic arm. The function of the wire feeder is to supply more metal wires to the arm and torch. The arm moves the torch to the cleaner, which cleans metal splatters that may solidify. This process happens while waiting for other parts of the metal that require welding.
To keep operators safe in the workplace while using the robotic welders, several safety features are available in the automated welding system. One of these safety features is the arc shield. This feature is used to prevent the high-heat arc from mixing with oxygen. Operators also need to be protected from bright lights and high temperatures. That is what enclosed areas are designed for.
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Robotic Welding Processes
High skill levels and expertise is required while operating a Weldsaver. However, it’s unfortunate that the demand for professional welders is higher than the supply. It is estimated that by 2022, there is going to be a shortage of 450,000 expert welders. This is according to The American Welding Society.
What makes the automated welding process better is the high accuracy, quicker delivery, and minimal waste of parts and materials. There is also a wide variety of equipment available. Robots can easily perform the welding processes using tools like spot, resistance, arc, TIG, and more.
The arch process of robotic welding is among the most common types. During this process, extreme heat of about 6,500 F° is generated by an electric arc, forcing the metal to melt. Parts of metal are joined together by the molten metal, solidifying after cooling to make the connection stable. When high accuracy is prioritized in a project, arc welding is the most appropriate technique. This process requires a proper welding water saver.
Robots may use resistance welding if the project is of a low budget or a need for heat-treating. In this process, an electric current pool of molten metal is created when it goes to two metal bases. The pieces of metal are joined together with the molten metal.
Not all materials that need welding can conduct electricity. This requires other forms of welding. This often happens in the automotive industry when joining body parts of an automobile. Valuation of resistance welding is done using a single spot to join two metal sheets.
TIG welding is normally used in robot welding applications that need high precision levels. This technique is also called gas tungsten arc welding or GTAW. The process involves the passing of an electric arc between the metal base and a tungsten electrode.
Due to the increasing demand for metal products around the globe, manufacturers need to step up production. The introduction of robotic Weldsaver systems has made it easier for plants to produce high-quality metal products in a shorter period than manual welding. Besides quality and efficiency, robotic welding has also increased safety in workplaces.
MD: Knowing how robotic Weldsaver works is essential if you want to use automated welding in your workshop. If you require to learn more about robotic welding and how it works, read this post.