Robotic Welding

Robotic welding system plays a critical role within the automotive industry. World’s Top Industrial Robotic Welding Manufacturers are Comau Robot, ABB Robot, Yaskawa Robot, Kuka Robot, Fanuc Robot and Nachi Robot.

Within a manufacturing environment, two types of welding robots generally get used. A semiautomatic and automatic robotic welding system each have a role.

The semiautomatic robotic welding system relies on human control for smaller-scale jobs. The controller will set the parameters for the robot to perform a simple operation. When complete, the person in control will handle the finished part.

DNC Automation provide best robotic welding systems in the industrial sector, being driven mainly by the automotive sector for the last several decades. Robotic welding is most productive when completing high-volume, repetitive welding tasks. Comau Robot Controller is able to communicate with Fronius and Magmeet welding controller by DeviceNet which will able to provide best performance on welding result.

Read more about robotic welding in automotive industry

Robotic Welding Applications

How Robotic Welding Works?

There are different types of robotic welding, but most facilitate automation through the use of CNC technology (computer numerical control). Firstly, the parts to be welded will need to have some kind of jig or fixture to hold them in place. Once they are fit in place, the programming can begin. The operator will use the pendant to adjust the articulating head of the robot. Each movement of the weld needs to be programmed into the pendant. The software is based on computer numerical control (CNC). This means that when each step is recorded, the coordinates of the position of the robotic welding head will be remembered. The operator will build a whole sequence of these movements to create a program for a certain weldment.

Certified human operators still need to remain close to the robots. These workers should hold certification from the American Welding Society, AWS, which certify not only manual welders but also robotic welding arm operators. The operators program the controller using a teach pendant. This device sets new programs, moves the arm and changes parameters for the process. To start the welding, the operator uses the buttons on the operation box.

The tool in the robotic arm heats to melt metal to conjoin the desired pieces. As needed, a wire feeder delivers more metal wire to the arm and torch. When awaiting the next parts to weld, the arm moves the torch to the cleaner to clean any metal splatters from the arm, which could solidify in place without this process.

Because one of the primary reasons to have robotic welders is protecting human workers, these automated systems come with multiple safety features. Arc shields prevent the high-heat arc from mixing with oxygen. Enclosed areas protect operators from the temperatures and bright light.

What are the Different Types of Robotic Welding?

There are several different types of robotic welding processes, each with its own benefits and types of applications.

Arc Welding
An electric arc between an electrode and metal base produces an intense heat to melt and intermix two parts. Arc welding is used for applications calling for high accuracy and repeatability.

Resistance Welding
A current is passed between two metal pieces of metal, a pool is formed by the resulting heat, and the two pieces are joined together. Resistance welding is the most economical form of robotic welding and is best for heat-treating projects.

Spot Welding
A type of resistance welding, spot welding joins thin metals that resist electrical currents. It’s typically used in the automotive industry to join sheet metal frames together.

TIG Welding
A high-quality process where an arc is formed between a non-consumable tungsten electrode and the metal part. Also known as Gas Tungsten Arc Welding (GTAW), TIG welding is used when precision is of the utmost importance.

MIG Welding
A high deposition rate process that involves feeding a wire continuously toward the heated weld tip. Also known as Gas Metal Arc Welding (GMAW), it is best for applications where system simplicity and speed are desirable.

Laser Welding
A laser generator delivers via a fiber optic cable a laser light through a robotic cutting head to weld pieces together. Laser welding, including remote laser welding for hard to reach weld locations, is often used in high volume applications that require high accuracy, such as the automotive sector or in the medical or jewellery industries.

Plasma Welding
Ionized gas passes through a copper nozzle to produce extremely high temperatures. Plasma welding is used when flexibility is required, as velocity and temperatures can be easily adjusted.