Automate your welding process

Automate your Welding Process Full Automation Magazine Co-MERCX broadcast Welding is a process where 2 materials are fused together through heating, intermixing, and then cooling the materials and/or a filler to form a strong join. From arc welding to spot welding, new and used welding automation machines and robots are typically used in welding processes where the weld required is repetitive and quality and speed are crucial. automation welding is an automated process that increases efficiency, consistency, and your return on investment (ROI). Welding automation uses robots to increase the performance of the production of welds. This automated welding process increases the speed, precision, quality and also minimises the chance of errors or inconsistent welds compared to manual welding. Automation can be applied to many different processes. ll types of welding can be automated, many times this is done with robots, but it's done with other types of automation as well, work stations, conveyor belts with multiple thrusters, robots that just move parts into position to be welded. There are 4 main types of welding. MIG – Gas Metal Arc Welding, TIG – Gas Tungsten Arc Welding, Stick – Shielded Metal Arc Welding and SAW – Flux-cored Arc Welding. 1

Automate your Welding Process Full Automation Magazine Co-MERCX broadcast Automated welding can provide large gains in productivity and profitability in the right applications. Welding is arguably the most complex manufacturing process and is frequently the least understood. A surprising number of companies spend millions of dollars to automate assembly while ignoring the welding process. Manual welding is still the best process for many assemblies. However, many assemblers are implementing automated welding systems to increase quality, productivity and profitability. Welding automation can be broken down into three basic categories: • Semiautomatic welding, • Fully automatic welding, • Robotic Welding. In semiautomatic welding, an operator manually loads the parts into the welding fixture. A manupilator controls then keeps the welding process, motion of the torch, and stillness of the parts to preset parameters. After the weld is completed, the operator removes the completed assembly and the process begins again. In fully automatic welding, a custom machine, or series of machines, loads the workpiece, indexes the part or torch into position, accomplishes the weld, monitors the quality of the joint and unloads the finished product. Additional \"part in place\" and final product quality checks may also be designed into the machine if necessary. Depending on the operation, a machine operator may be necessary. Automating the torch or part motions, and part placement, reduces the possibility of human error. A weld takes place only when all requirements are satisfied. 2

Automate your Welding Process Full Automation Magazine Co-MERCX broadcast With manual welding, reject welds often increase when welders become fatigued. Depending on the value of the parts when they arrive at the welding station, the cost savings in scrap alone may justify the purchase of an automated welding system. Automation should also be considered when assemblers need to minimize the risk of shipping a bad part to a customer. Semiautomatic and fully automatic systems increase output by eliminating the human factor from the welding process. Production weld speeds are set at a percentage of maximum by the machine, not by an operator. With minimal setup time and higher weld speeds, a mechanized welding system can easily outpace a skilled manual welder. Reliance on human welders can dramatically increase a manufacturer’s labor costs. When planning for labor costs, manufacturers must consider the time that welders spend producing assemblies. Typically, a semiautomatic system has at least twice the output of a skilled welder. A fully automatic system can be built with twin welding positioners on an automated shuttle. Such a system can load and unload parts at one station while welding occurs at the other. In this way, a fully automatic system can run at four Arial the pace of semiautomatic system, or eight Arial the pace of a skilled welder. Lost opportunity costs are also significant. If a skilled welder fails to report to work, the company’s variable costs skyrocket. 8 hours of production time is lost. Availability of skilled labor for manual welding may also pose a challenge. Conversely, general machine operators are more readily available and more affordable than skilled labor. 3

Automate your Welding Process Full Automation Magazine Co-MERCX broadcast A basic robotic welding system is formed by 2 subsystems: * The welding equipment delivering the energy from the power source to the workpiece, * The robot providing relative positioning of the heat source and the workpiece. Normally 6-axis industrial robots are used, since they enable the welding torch mounted at the wrist to achieve all the positions necessary for 3D-dimensional welding. Traditionally, general purpose industrial robots are employed, carrying arc welding torches as end effectors. Many robot manufacturers have recently developed arc welding-specific robots, which are smaller and less expensive. Not every welding operation is a good candidate for automated welding. Applications will benefit most from automation if the quality or function of the weld is critical; if repetitive welds must be made on identical parts; or if the parts have accumulated significant value prior to welding. Automated welding systems offer 4 main advantages: * Improved weld quality, * Increased output, * Decreased scrap, * Decreased variable labor costs. Weld quality consists of 2 factors: * Weld integrity, * Repeatability. 4

Automate your Welding Process Full Automation Magazine Co-MERCX broadcast Automated welding systems ensure weld integrity through electronic weld process controllers. Combining mechanized torch and part motions with electronic recall of welding parameters results in a higher quality weld than can be accomplished manually. Based on years of design experience, WELDERMASTER automated welding system with robot is made for multiple types of welding situation. In a production environment, WELDERMASTER workpiece manipulators are frequently implemented as part of the robotised system. The devices extend not only a welding robot’s working range but also its accessibility, especially when welding complex and large geometries. Sensing technologies designed for welding and its automation are the essential elements for enabling this desired level of control. The sensors are applied to observe and measure process parameters, acting as the sources of input to the control system. By acquiring and analysing the input information from the sensors, the control system adapts output of the robotised welding process in accordance with the defined welding procedure specifications. There are various types of sensors available for robotic arc welding applications. Depending on their functions, the sensors are classified into 2 categories: * Process sensors: The former measure the process parameters of the robotic welding process (eg arc voltage, current, wire feed speed and torch rotation), which determine the stability of the process. * Geometrical sensors: The weld joint geometry (eg gap sizes, weld size changes, deviation from the nominal path and orientation changes) and are used for weld searching, seam tracking and real-time adaptive welding. 5

Automate your Welding Process Full Automation Magazine Co-MERCX broadcast Robot sensors measure robots’ condition and its environment and inform robots controller as electronic signals. Robots need sensors to control themselves. Typical sensors used in robotic arc welding Function Sensor Welding Current Hall effect sensor Measurement Current shunt Arc Length Control Voltage sensor Distance Control Capacitive sensor Weld Edge Tactile (electrical contact) sensor Searching Proximity sensor Tactile (mechanical contact) probe Weld Seam Eddy current sensor Tracking Through-arc sensing (weaving with electric measurement) Vision sensor Laser scanning Weld Penetration Infrared radiation sensor Monitoring Ultrasonic sensor Vision sensor Weld Pool Thermal imaging Monitoring Eddy current sensor Ultrasonic sensor Weld Quality Inspection Laser scanning The Intelligent Robot Controllers, designated as a common platform for industrial robots and enabled robots to move without programming collaborating with major robot makers. 6

Automate your Welding Process Full Automation Magazine Co-MERCX broadcast After scientifically rearranging the internal structure, all cables and components now are well protected from all sorts of external device interference, which makes it stable and reliable when it works in narrow space. WELDERMASTER has also integrated rapid welding process deployment, welding after interruption, intelligent weaving welding, positioner linkage and collision prevention and other functions. Arc welding utilizes an electric arc between an electrode and a metal base using either consumable or non- consumable electrodes. An arc welding robot uses a process which applies intense heat to metal at a joint, causing the metal to melt and intermix. Robotic welding is a challenging combination of welding, robotics, sensor technology, control systems and artificial intelligence. Robotic welding was designed to ease the production efforts for welders and facilities throughout the industry. In a world where technology continues to advance, the manufacturing industry has taken advantage of robotic welding benefits. With speed and accuracy being two of the most important goals in all welding operations, robotic welding has grown as a \"go-to\" leading application process. Robotic arc welders are more consistent throughout the weld and provide impeccable repeatability, providing higher quality welds. Robots can also save workers from health hazards by limiting exposure to fumes and decreasing risk of arc burn. Robot welding decreases cycle times and enhances efficiency. The return on investment (ROI) is worth every penny spent on an arc welding robot. 7

Automate your Welding Process Full Automation Magazine Co-MERCX broadcast Accuracy, efficiency, and repeatability describe the primary benefits that go along with installing a robotic welding cell into your work processes. The productivity increase for manufacturers across the world has led automated welding systems to be adopted in high numbers. As the number of welders continues to decrease in comparison to the demands of the industry, a need for automation has been sought at increasingly high rates. Driven by the increasing demands of improved quality, productivity and flexibility, precise and adaptive control of the robotic welding processes has become a crucial target for the development of automation systems. Automate your welding of the panels, sub-assemblies and H/T-profiles in the building industry with WELDERMASTER Gantry Systems. Mech. Engr. Erdinc Cihan Autoweld Advisor Co-MERCX Machinery Ltd Weldermaster Robotic www.commercx.com 8