Beruflich Dokumente
Kultur Dokumente
Lecturer:
Dr Ing Yupiter HP Manurung
Group Members:
Laser Welding
Spot Welding
Automation of Welding
Automated welding system consists of:
2. Welding arc
3. Master controller
7. Welding program
8. Consumables
Some of the equipment of the robotic
Robotic Welding Concept
A special kind of electrical power is
required to make an arc weld.
The nozzle of the torch is close to the
arc and will gradually pick up spatter.
A torch cleaner (normally automatic) is
often used to remove the spatter.
All of the continuous electrode wire arc
processes require an electrode feeder
to feed the consumable electrode wire
into the arc.
Robotic Welding Concept
Welding fixtures and workpiece manipulators
hold and position parts to ensure precise
welding by the robot.
The productivity of the robot welding cell is
speeded up by having an automatically
rotating or switching fixture
Workcell
Typical Arc Welding Robot
ARC MOTION DEVICES
The machine moves the arc, torch and
welding head along the joint.
The person or operator performs a
supervisory role and may make adjustments
to guide the arc, manipulate the torch and
change parameters to overcome deviations.
Since the person is partially removed from the
arc area, higher currents and higher travel
speeds can be used.
The fatigue factor is reduced and the operator
factor is increased. Productivity increases with
a resulting reduction of welding costs. Arc
motion devices fit into 5 categories:
- Manipulator (boom and mast
assembly)
- Side beam carriages.
- Gantry or straddle carriages.
The arc motion devices carry the welding head
and torch and provide travel or motion relative to
the weld.
They are used for continuous wire processes, gas
metal arc, flux-cored arc and submerged arc
welding and also for gas tungsten and plasma arc
welding.
The motion device must be matched to the
welding process.
Gas tungsten and plasma arc welding require
more accurate travel and speed regulation.
This must be specified because tighter tolerances
are used in manufacturing and the equipment will
be more expensive.
MANIPULATOR
consists vertical mast and a horizontal boom that carries the
welding head. They are sometimes referred to as boom and mast
or column and boom positioners. Manipulators are specified by
two dimensions:
The maximum height under the arc from the floor.
Maximum reach of the arc from the mast.
They are many variations of manipulators. The assembly may be
mounted on a carriage that travels on rails secured to the shop
floor. The welding power source is usually mounted on the
carriage.
The length of travel can be unlimited thus the same welding
manipulator can be used for different weldment by moving from
one workstation to another.
In selecting and specifying a welding manipulator, it is important
to determine the weight to be carried on the end of the boom and
how much deflection can be allowed.
The welding torch should move smoothly at travel speed rates
compatible with the welding process.
The manipulator carriage must also move smoothly at the same
speed. Manipulators are one of the most versatile pieces of
welding equipment available.
They can be used for straight-line, longitudinal and transverse
SIDE BEAM CARRIAGE
Less expensive and less versatile than the boom
and mast manipulator.
The side beam carriage performs straight-line
welds with longitudinal travel of the welding head.
Side beam carriages are available with high-
precision motion depending on the accuracy used
in the manufacture of the beam and the speed
regulation of the travel drive system.
The carriage will carry the welding head, wire
supply and so on and the controls for the operator.
The welding head on the carriage can be adjusted
for different heights and for in-and-out variations.
The welding arc is supervised by the welding
operator who makes adjustments to follow joints
that are not in perfect alignment.
The travel speed of the side beam carriage is
adjustable to accommodate different welding
procedures and process.
Precision side beam carriage Side beam carriage
GANTRY OR STRADDLE
CARRIAGES
Gantry arc welding machines are motion devices that
provide one or two axes of motion.
It consist horizontal beam supported at each end by a
powered carriage. The gantry structure straddles the
work to be welded and the carriages run on two
parallel rails secured to the floor.
This provides the longitudinal motion and can be quite
long. The length of the gantry bridge determines the
width of the parts that can be welded.
The torches are mounted on carriage that moves
along the gantry beam. This provides the transverse
motion.
The travel speed of the carriages must be smooth and
match the welding speed of the welding process.
The one or more welding heads on the gantry bridge
will have power travel or will have adjusting devices to
locate the head over the weld seam.
Usually a maximum of two torches are provided for
transverse motion. And vertical motion should be
available for adjustment.
Gantry Welding Machine FSW gantry at Eclipse
Aviation for welding stringers
and spars to aluminium cabin
panels
TRACTORS FOR FLAT-
POSITION WELDING
A welding tractor is an inexpensive way of
providing arc motion.
Tractors are commonly used for mechanized
flame cutting. Some tractors ride on the material
being welded while others ride on special tracks.
The tractor should have sufficient stability to carry
the welding head, the electrode wire supply, flux
and the welding controls.
This method popular in shipyards and in plate
fabricating shops.
The travel speed of the tractor must be closely
regulated and smooth and related to the welding
process.
It must have sufficient power to drag cables. A
more specialized tractor carries two heads.
Figure: Welding tractor for SAW Figure: Welding tractor, gun and track.
CARRIAGES FOR ALL-POSITION
WELDING
There are many requirements for mechanized vertical
or horizontal position welding.
The gun is connected to the wire feeder by means of
the standard cable assembly. In this case, an oscillator
is employed to provide lateral arc motion.
This type of welding carriage can be used in the flat,
vertical, horizontal or overhead positions.
Adjustments can be made to align the torch to the joint
and for maintaining this alignment. The track can be
attached to the work with magnets or vacuum cups.
A special carriage known as a skate welder is
designed to follow irregular joints contours inside
complex structures.
Skate welder travel units are extremely compact and
carry a miniaturized wire feeder or only a torch.
Skate welders are used for welding inside aircraft
assemblies.
Figure: Overhead Figure: Horizontal
Figure: Vertical
Arc Welding Robot
Gantry - These robots have linear joints and are
mounted overhead. They are also called Cartesian
and rectilinear robots.
Cylindrical - Named for the shape of its work
envelope, cylindrical anatomy robots are fashioned
from linear joints that connect to a rotary base
joint.
Polar - The base joint of a polar robot allows for
twisting and the joints are a combination of rotary
and linear types.
Jointed-Arm -The arm connects with a twisting
joint, and the links within it are connected with
rotary joints. It is also called an articulated robot.
Figure of Industrial Robot
Robot Safety
Depending on the size of the robot’s work
envelop, speed, and proximity to humans.
safety considerations in a robot environment
are important and particularly for
programmers and maintenance personal who
are in direct physical interaction with robots.
Control For Automatic Arc Welding
• A control system is required to run the
welding program.
• Mechanized and automatic welding have
more complicated programs and control
additional functions, including travel or
motion, torch position and fixture motion.
• Adaptive welding, which varies weld
parameters in accordance with actual
conditions, has a complicated computer
control system that include sensing devices
and adaptive feedback.
• In semiautomatic, welding a control
mechanism in the wire feeder actuates
electrode wire feed and starts the welding
current and shielding gas flow when the
welder presses the gun trigger.
Automatic Welding Controllers
Programmers are designed to execute a welding program. As the welding
program becomes more complex, the controller must include more
electrical circuits.
To fully understand a welding program, it is necessary to understand the
terms used:
Preflow time: The time between start of shielding gas flow and arc
starting(prepurge).
Start time: The time interval prior to weld time during which arc voltage
and current reach a preset value greater or less than welding values.
Start current: The current value during the start time interval.
Start voltage: The arc voltage during the start time interval.
Hot start current: a brief current pulse at arc initiation to stabilize the arc
quickly.
Initial current: The current after starting buty prior to upslope.
Weld time: The time interval from the end of start time or endof upslope
to beginning of crater fill time or beginning of downslope.
Travel start delay time: The time interval from arc initiation to the start
of work or torch travel.
Crater fill time: The time interval following weld time but prior to
burnback time, during which arc voltage or current reach a preset value
greater or less than a welding values. Weld travel may or may not stop
at this point.
Crater fill current: The arc current value during crater fill time.
Burnback time: The time interval at the end of crater fill time to arc
outage, during which electrode feed is stopped. Arc voltage and arc
length increase and current decreases to zero to prevent the electrode
from freezing in the weld deposit.
Downslope time: The time during which the current is changed
continuosly from final taper current or welding current to final current.
Upslope time: The time during which the current change continuosly
from initial current value to the welding value.
Postflow time : Time interval from current shutoff to shielding gas.
Weld cycle time: The total time required to complete the series of
events involved in making a weld from beginning of preflow to end of
postflow.
WELDING CONTROLLER
Robot Controller
For robotic arc welding system, a much more
complex controller is required.
Controller include a high speed
microprocessor since coordinated,
simultaneous, continuos motion of up to eight
axis and all welding parameters may be
required.
Robot Controller
Robot Controller
The machine tool industry introduced numerical control(NC) years ago,
these are known a Point To Point(PTP) control system.
Point are location in two dimension in one plane
For arc welding robot, the arc is moved from one point to the next in
space.
The location of the arc is known as the tool center point(TCP)
The path of the TCP is programmed and stored in memory.
For spot welding, pick and place and machine loading, point to point
playback is used.
For arc welding, playback of the arc motion is a continuos path in space.
The robot controller must be cooerdinated so that each axis movement
begins and end at the same time.
Programmer Function
accept the input of many point locations.
relate welding parameter to the path tought.
store this information in memory.
play it back to execute a welding program.
The major points of interest are the teach
mode, memory and playback or execution.
The method of teaching or programming the robot
controller:
Manual method: The manual method is not used for arc welding robot
but it is used mainly for pick and placed a robots.
Walk through: The walk through method requires the operator to move
the torch manually through the desired sequence of movement. . Each
move is recorded into memory for playback during welding. The welding
parameter are controlled at appropriate positions during the weld cycle.
Lead through: The lead through method is a popular way in
programming a robot. The robot welding operator accomplishes this
using the teach pendant. By means the keyboard on the teach pendant,
the torch is driven through the required sequence of motion. In addition,
operator inputs electrode wire speed, arc voltage, arc on, counters,
output signals, job jump function and much more. All of this function are
related to a particular point along the taught path. In this way, if the
speed of robot is changed, it is not necessary to change the time for
certain actions to happen.
Off-line programming:
Off-line programming involves the preparation of the program on a
computer. An appropriate languages must be used. The program is
entered into the robot memory very quickly. This increase the use of the
robot,since lead-through teaching ties up the robot during programming.
Off line programming is becoming more widely used, but requires
experienced personnel.
Teach Pendant
Weld Execution
1) Weld can be made only when the power is on all components,
electrode wire is installed, and the controller is in playback or operate
mode
2) The material must be in the fixture and ready
3) Pushing the start button will initiate the operation
4) The robot will move the torch to the start point.
5) The welding equipment will begin its cycle of operation (gas preflow,
start the arc).
6) The robot controller will determine that the arc has started and then
start motion.
7) Points along the taught path will initiate other activities programmed
8) At the end of the taught path, the welding equipment will terminate the
weld program and the robot controller will determine that the
electrode wire has separated from has separated from the work
1) After this the robot will return to its home
position, ready for another cycle.
2) At this points the weld should be checked for
quality.
3) The program should be checked and edited
to improved the weld if necessary and to
minimize the air cut path and increase air cut
speed.
4) When the weld quality is acceptable and
cycle time is at a minimum, it is time to freeze
the program and start production.
Programming Robotic
Welding