The Basics of Robotic Welding
and the Robotic Weld Cell
Robotic Welding is Best when Production Rates are Rising
Welding with a robot, as an alternative to manual welding, can be
considered, for instance, if production rates are increasing and it looks as if
the existing manual process, lends itself to automation.
The existing process (preferably G.M.A.W.) has been proven, thus reducing
the learning curve.
It is a normal move, to try and use existing manual fixtures, in the automated
cell, but this maybe a false economy. In order to keep cycle times to a
minimum, automatic, pneumatic part clamping, is usually employed, along with
some form of reliable, fail safe part sensing. Such features may not be
found in a simple, manual fixture.
The justification for such a move, is, as always, a case of R.O.I.
(Return on Investment.)
An R.O.I. of longer than 12 months can be difficult to justify. However, other
advantages should be kept in mind - such as uniformity of parts, lower scrap
rates and higher part quality.
A typical robot welding cell, will consist of:
- A rotary, oscillating device.
This moves a
weld fixture, from the loading area into the robot's work envelope,
and thus, in the same motion, returns a finished part, to the operator.
An oscillating motion is preferred, compared to a continuous rotary motion, as
the air and electrical connections, to the fixtures, are simplified.
-
The Weld Fixture
In reality, there will be a minimum of 2-fixtures and could be many more,
depending upon cost and cycle time requirements.
- The Robot.
The robot is usually a
6-axis type, which is available with a range of different
work envelopes. For more information on these robots-click
here.
- The Enclosure.
This is required to ensure operator safety and protect other personnel from
light, spatter etc. A light curtain, is generally used at the operator station.
This gives maximum access and a fail safe "intrusion barrier"
For further information on robotic welding, try these links:
ABB
Fanuc
Panasonic
Kuka
Motoman
It should be pointed out, that all of the above manufacturers, offer a generic,
robotic, work cell.
These "off-the shelf" units usually only need the addition of fixtures to
complete and thus offer an extremely cost effective method of automating.
Please note that the above listed companies are by no means the only
manufacturers, nor the only ones we have used, over the years, but they do make an
excellent product, THAT IN THE CORRECT APPLICATION, should give years of trouble
free service.
To find out more
about how your company can benefit from robotic welding, please feel free to contact us.
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