ROBOT WELDING TECHNOLOGY

(ROBOTIC WELDING)

Submitted To :- Submitted By :-
Mr. Rajan Karir Chandra Prakash Sharma (15/084)
CONTENT
1. Introduction
2. Components Of Robotic Welding
3. Feature Of Robot Welding
4. Sensor
5. Benefit Of Robot Welding
6. Factors For Setup A welding Robot Unit
7. Conclusion
INTRODUCTION :-
 Robot welding is the use of mechanized programmable tools (robots), which
completely automate a welding process by both performing the weld and
handling the part.
 The large bulk of materials that are welded are metal and their alloys although
welding is also applied to the joining of other materials such as thermoplastics.
 Welding joins different metals or alloys with help of a number of processes in
which heat is supplied either electrically or by means of a gas torch.

Why robot welding use?

• The most prominent advantages of automated welding are precision and productivity.
Robot welding improves weld repeatability.
• Robots work well for repetitive tasks or similar pieces that involve welds in more than
one axis or where access to the pieces is difficult.
• Once programmed correctly, robots will give precisely the same welds every time on
workpieces of the same dimensions and specifications.
• Automating the torch motions decreases the error potential which means decreased scrap
and rework.
• With robot welding you can also get an increased output. Not only does a robot work
faster, the fact that a fully equipped and optimized robot cell can run for 24 hours a day,
365 days a year without breaks makes it more efficient than a manual weld cell.
• Another benefit of automated welding is the reduced labor costs. Robotic welding also
reduces risk by moving the human welder/operator away from hazardous fumes and
molten metal close to the welding arc.
• There are two types of robot weldings :-

• 1)arc welding

• 2)spot welding
TYPICAL COMPONENTS OF AN INTEGRATED ROBOTIC
WELDING : -
1. welding robot
2. Power source/Welding swivel
3. Welding torch/gun
4. Wire feeder
5. Welding fixtures and work piece positioners
6. Torch cleaner
7. TCP calibration unit
WELDING ROBOT :-
There are two popular types of industrial welding robots :-
1) Articulating robots
2) rectilinear robots.
Robotics control the movement of a rotating wrist in
space. Rectilinear robots move in line in any of three axes (X,
Y, Z). In addition to linear movement of the robot along axes
there is a wrist attached to the robot to allow rotational
movement. This creates a robotic working zone that is box
shaped.
Articulating robots employ arms and rotating joints. These
robots move like a human arm with a rotating wrist at the
end. This creates an irregularly shaped robotic working zone.
 A TYPICAL WELDING ROBOT :-
.  .
CONTROL SYSTEM:-
• In adaptive control welding, i.e., a closed loop system using feedback-sensing devices and adaptive control.
• There is a process control system that detects changes in welding conditions automatically with the aid of
sensors and directs the equipment to take appropriate action.
• Sensors are needed in adaptive control welding to find the joint, assess root penetration, conduct bead
placement and seam tracking, and ensure proper joint fill
 Power. source/ Welding Swivel:-
A welding power source must deliver controllable current at a voltage
according to the requirements of the welding process. Normally, the power
required is from 10 to 35 V and from 5 to 500 A.
A major advancement in resistance spot welding is the swivel. This unit
permits passage of compressed air, cooling water, electric current and
signals through different channels within a single rotating unit.
 Welding torch/gun:-
A welding torch is used in an automatic welding system to direct the
welding electrode into the arc, to conduct welding power to the electrode,
and to provide shielding of the arc area.
Spot welding guns are normally designed to fit the assembly. Many basic
types of guns are available, the two most commonly used being the direct
acting type, generally known as a “C”-type gun, where the operating
cylinder is connected directly to the moving electrode, and the “X”-type
(also known as "Scissors" or "Pinch") where the operating cylinder is remote
from the moving electrode, the force being applied to it by means of a lever
arm.
.

 WIRE FEEDER:-
Wire feeders are used to add filler metal during robotic welding.Normally, the wire
feeder for robotic welding is mounted on the robot arm, separate from the power supply.
 WORKPIECE FIXATION AND POSITIONING:-
In order to join parts successfully in a robotic welding application, individual parts must
be aligned precisely and held securely in place while the welding is proceeding. An
important consideration, then, is the design of a fixture which holds the individual parts
in the proper alignment.
 TORCH CLEANER:-
Periodic cleaning of arc welding guns is required for proper and reliable operation of
robotic arc welding equipment. Systems are available that spray an antispatter agent
into the nozzle of the gun. Additionally, tools that ream the nozzle to remove
accumulated spatter and cut the wire are available. The cleaning system is automatically
activated at required intervals by the welding control system.
 TCP-CALIBRATION UNIT:-
End-of-arm sensor and tool centre point calibration is a critical aspect of successful system
implementation. End-of-arm sensing, in the context of robotic welding, is used to detect the actual
position of the seam on the workpiece with respect to the robot tool frame.
FEATURES OF WELDING ROBOTS :-

 WORK VOLUME AND DEGREES OF FREEDOM

 MOTION CONTROL SYSTEM

 PRECISION OF MOTION

 PROGRAMMING

 INTERFACE WITH OTHER SYSTEM

SENSOR FOR WELDING ROBOTS:-
Sensor Type Sensor

Contact type Mechanical Type - Roller Spring. Electromechanical type:

(Weld seam tracking) 1) Two probes across the seam line.
2)A probe in the seam line. Electric control type with probe.

Non-contact type A. Physical type:

(Various Purposes) 1) Acoustic – arc length control.
2) Capacitance – distance control.
3) Eddy current –seam tracking.
4) Induction – seam tracking.
5) Infrared radiation – penetration control.
6) Ultrasonic – penetration and weld quality.
7) Magnetic – detecting electromagnetic field.
B. Through-the-arc type:
1) Arc length control (arc voltage).
2) Weaving with electric measurement (GTAW, GMAW).
C. Optical/vision (image capture and process):
1) Vision sensors.
2) Laser sensors.
3) Opto-electric sensors.
BENEFITS OF ROBOTIC WELDING :-

 Greater Quality Of Product.

 Improved Safety And Quality Of Work Life.
 High Production Rate.

 Increases the flexibility

 It reduces welder fatigue and welder exposure to the more hazardous atmosphere.

 It Reduce The Welding Defects.

• .Factors that need to be considered when setting up a robotic welding facility.:-
Robotic welding needs to be engineered differently than manual welding. Some of the
consideration for a robotic welding facility are listed below:
1. Accuracy and repeatability
2. Number of axes
3. Reliability
4. Fixtures
5. Programming
6. Seam tracking systems
7. Maintenance
8. Controls
9. Weld monitors
10. Positioners
 CONCLUSION:-
 A substantial opportunity exists in the technology of robotics to relieve people
from boring, repetitive, hazardous and unpleasant work in all forms of a
human labor.

 Properly applied, robots can accomplish routine, undesirable work better than
humans at a lower cost

 Not only will robotics improve our standard of living, it will also improve our
standard of life.
THANK YOU