Notes on Welding Manipulator Operation

With the advent of smart manufacturing and the era of big data, many welding operations are being carried out using welding manipulators. For companies facing the need to transform from manual to automated welding. The following is an explanation of the considerations for the operation of the welding manipulator.

How to program and operate the welding manipulator?

1. Select a reasonable welding sequence to reduce welding deformation and develop a welding sequence for the length of the gun travel path.

2. The spatial transition of the welding gun requires a short, smooth and safe motion path.

3. In order to obtain the best welding parameters, working specimens for welding tests and process evaluation are made.

4. A reasonable position of the positioner, torch attitude, and torch position relative to the joint is used. After the workpiece is fixed on the positioner, if the weld is not the ideal position and angle, the programming requires continuous adjustment of the positioner so that the weld reaches the horizontal position one by one according to the welding sequence. At the same time, the position of each axis of the welding manipulator should be adjusted continuously to reasonably determine the position, angle, and extension length of the welding gun relative to the joint. After the position of the workpiece is determined, the position of the welding gun relative to the joint must be observed through the eyes of the programming technician.

5. Timely insertion of the gun cleaning procedure: After the welding operation reaches a certain length, the gun cleaning procedure should be inserted in a timely manner. Prevent welding spatters from clogging the welding gun and conductive nozzle. Ensure the cleanliness of the welding gun, and improve the service life of the welding gun. Ensure reliable arc initiation and reduce welding spatter.

6. During the robot welding process, only by constantly checking and modifying the program, adjusting the welding parameters, and gun attitude, can a smooth-running program be formed.

Safe Operation of The Welding Manipulator

1. The staff operating the welding manipulator must be familiar with the performance, structure, and transmission system of the equipment, and operate with a certificate.

2. Lubricate the welding manipulator frequently.

3. Before we use the welding manipulator to weld the workpiece, a trial run is required. Check whether the cross arm moves up and down, left and right, limit and speed adjustment are normal, whether the movement is stable, and whether the head adjustment is normal. Check whether the flux recovery device is normal. Check whether the voltage and current adjustment of the welding machine are normal.

4. It is strictly forbidden to stand under the cross arm and around the roller frame when the welding manipulator is welding.

5. When the welding manipulator is rotating, pay attention that the power supply line pipe is crushed and damaged.

6. Regardless of whether it is stretching, lifting, or rotating when you need to change the direction, you must first switch to the stop position and then change the direction.

7. When using the welding manipulator, if any abnormality is found. If vibration, abnormal sound, jamming, etc., stop immediately and notify for inspection and repair.

8. For the welding of various welds refer to the welding process.

9. During the welding process of the welding manipulator, the flux needs to be manually added according to the amount of use, and the flux recovery device is used at the same time.

10. After the welding manipulator is used, the beam needs to be lowered to the equilibrium position, the center of gravity is kept stable, and then the power supply is cut off.

11. Store the flux in the designated place after recycling.

12. Place the welded workpiece at the designated position.

13. Carefully do a good job in cleaning and sanitation of equipment and venues.

Welding manipulator common fault analysis

1. Welding gun collision: It may be due to workpiece assembly deviation or inaccurate welding gun TCP. Check whether the assembly or TCP of the welding gun is correct.

2. Excessive spatter: It may be due to improper selection of welding parameters, gas composition reasons, or excessive wire elongation. The machine power can be properly adjusted to change the welding parameters; the gas ratio mixer can be adjusted to adjust the gas mixture ratio; the relative position of the welding torch and the workpiece can be adjusted.

3. Protective gas monitoring alarm: Check whether the cooling water or protective gas pipeline has cooling water or protective gas supply failure.

4. Welding deviation problem: It may be caused by incorrect welding position or problems in finding the welding gun. At this time, you need to consider whether the center point of the welding gun is accurately positioned and adjusted. If this happens frequently, it is necessary to check the zero position of each axis of the welding robot and recalibrate it for correction.

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