Laser Technology

The use of welding robots can not only stabilize and improve welding quality and increase production efficiency, but also reduce the skill requirements for welders, thereby shortening the preparation cycle for product upgrades and reducing corresponding equipment investment. When using robotic welding equipment, problems such as off-center welding and undercut may occur due to improper operation or equipment damage. So, how should these problems be handled? To help users deal with these problems encountered in the use of welding robots, let's take a closer look at the specific content below.

Off-center welding may be due to incorrect welding position or problems with the welding torch search. In this case, consider whether the TCP (center point position of the welding torch) is accurate and adjust it accordingly. If this happens frequently, check the zero position of each axis of the robot and recalibrate it. Undercut may be due to improper selection of welding parameters, incorrect welding torch angle or position, which can be adjusted appropriately. Poor gas shielding, excessively thick primer on the workpiece, or insufficient drying of the shielding gas can also be caused by these issues; appropriate adjustments will resolve the problem. Excessive spatter may be caused by improper welding parameters of the welding robot, gas composition issues, or excessively long welding wire extension. 

Adjusting the machine power can modify the welding parameters, adjusting the gas ratio using the gas meter, and adjusting the relative position of the welding torch and workpiece can help. For the issue of an arc crater forming at the weld end after cooling, a submerged arc crater function can be added to the programmable steps to fill it. Gun collisions may be due to workpiece assembly deviations or inaccurate welding torch TCP (Torch Control Point). Checking the installation or modifying the welding torch TCP can help. Arc defects and inability to ignite the arc may be due to the welding wire not contacting the workpiece or excessively low process parameters. Manual wire feeding, adjusting the distance between the welding torch and the weld, or adjusting the process parameters can help.

 An alarm may indicate a problem with the shielding gas monitoring system, cooling water, or shielding gas supply. Checking the cooling water or shielding gas lines is crucial. Welding robot programming techniques should select a reasonable welding sequence to minimize welding deformation and determine the welding torch travel path length. Spatial transitions of the welding torch require a short and smooth movement track. To optimize welding parameters, test pieces are manufactured for welding experiments and process verification. Appropriate positioner orientation, welding torch posture, and welding torch position relative to the joint are adopted. After the workpiece is fixed on the positioner, if the weld seam is not in the ideal position and angle, the positioner needs to be continuously adjusted during programming to ensure the weld seam gradually reaches a horizontal position according to the welding sequence. 

Simultaneously, the robot's axis positions must be continuously adjusted to reasonably determine the welding torch position, angle, and wire extension length relative to the joint. After the workpiece position is determined, the welding torch position relative to the joint must be observed visually by the programmer, which is quite difficult. Timely torch cleaning programs are essential. After writing a welding program of a certain length, a torch cleaning program should be entered promptly to prevent welding spatter from clogging the welding nozzle and contact tip, ensuring torch cleanliness, improving nozzle life, ensuring reliable arc ignition, and reducing welding spatter. Programming generally cannot be completed in one step; it requires continuous checking and modification during robot welding, adjusting welding parameters and welding torch posture, etc., to create a good program. Personnel using welding robots should take precautions to avoid equipment damage, reduced work efficiency, and other issues. If such problems do occur, users can refer to relevant guidelines for scheduling and maintenance to ensure the welding robot can continue to operate normally and meet the needs of more users.