684 Modern Welding From these brief examples, the variety of processes and applications can be seen. Almost every welding process can be automated. Spot welding is the most common use of welding robots, Figure 26-9. The most common robotic arc welding process is GMAW. Other robots may perform automatic GTAW, plasma spray- ing. or are stud welding. All automatic welding oF cut ting machines rely on feedback controls, solenoids, relays, and motors to control and direct the automatic ‘welding process. 26.4 Introduction to Robots ‘The major reasons to use an automatic welding pro- cess are to inerease productivity, improve quality, and reduce cost. Industrial robots, usually referred to simply as robots, accomplish all three of these objectives ‘A robot used with an automatic welding pro- cess can weld faster and more accurately, and pro- duce welds of higher quality, than a human welding manually. This increases productivity. A robot per forms the same sequence of moves over and over and maintains the same travel speed and positioning every time. This improves the quality of the welding Figure 26-9. A resistance spot welding robot. operation and tends to produce fewer defects. Since the robot welds faster, makes better quality welds, and welds continuously, the cost af the welding oper- ation is reduced. In the right applications, the use of a robot makes good sense However, robots are not suited for every welding, application. Robots are good at repetitive tasks with parts in a repeatable location. It is not practical to build necessary fixtures and to teach a robot to weld low volume parts of those that are not repeatable. A large part often cannat be brought to a sabot, and the robot cannot go to the part like a welder can. A skilled welder produces a better and more economical weld than a robot in these situations, A robot is a complex and technical piece of equip- ment. A company must consider the cost, manpower, and training required to install, operate, and maintain a robot. The cost of implementing a robotic application must be judged against the benefits. For small custom ‘welding operations, a few skilled welders can perform better thana robot. 26.4.1 Robotic System ‘The robot itselfis only part of a complete robotic weld- ing system. The robotic system includes all the equip- ment and software needed to accomplish the welding, cutting, or surfacing task. This equipment is normally ssembled and located within what is called the robot ‘workcell, Figure 26-10, Equipment for a robot work: cell inchides the following: * Arobot + The electronic robot controller. + Automatic welding, cutting, or surfacing equipment + Apositioner (optional). + Fixtures to hold the part to be welded ‘+ Material handling equipment (optional). + Operator controls, + Safety screens and /or electronic barriers. Other items that may be needed to properly set up and maintain a robotic system include the following: ‘« Amaster part that is used to “teach” (program) the robot + Aprogram listing for the robot. * Amethod of saving a backup program, torch or gun setup jig to “zero” the robot + Atorch cleaning station. See Figure 26-11 + An inspection jig to check the finished parts. + Asetup and troubleshooting guide.Welging power supplies \. Salely light curtain ye: FP Operator Robot eontraliers _- contol panel Positioner - Figure 26-10. A robotic welding cell. The complete cell includes an are welding robet, controller, welding power source positioner, safety fencing, safety light curtains, and operator controls. 26.4.2 Robotic Movements An industrial robot is required to move the welding torch through a set of motions. The robot needs a tem to enable it to move. Most robots are connected to 2 480V or 240V electrical service. This electricity oper- ates electric motors used to move the robot about its various axes There are two common systems of robot motion. Oneis the rectilinear robot; the other is the articulated robot. rectilinear robot moves in straight lines in the "X." “Y,” and “Z" axes. Each axis is a joint or a degree of motion. See Figure 26-12. Robotic position- ing equipment can be a rectilinear robot, Teco Weal; Meaty Cone Figura 26-19 A ractilinear enbot showing the mations that ‘Anozzle cleaning station for a GMAW robot. can ba made in the "X7*Y? and "2" axes.686 Modern Welding The parts of an articulated robot rotate around various axes. By rotating different joints, the robot can reach virtually any point in a spherical zone sur- rounding it. The three-dimensional space a robot can reach is called the working volume. See Figure 26-13 and Figure 26-14 Most welding robots are articulated. Welding robots commonly have six axes. Sixaxes give the robot adequate freedom of motion and dexterity to complete mast tasks. Each axis does add cost to a robot, so some robots have only five axes. Some robots have additional ayes. Figure 26-13. An articulated robot's working volume. Sixaxis robot Positioner Socaxis robot Figure 26-14. Articulated robots are mounted on the tend of rectilinear robots. There are two robots welding in this application, one on either side of the structure. ‘The combination of a welding arficulated robot mounted on arrectifinear robot creates the working volume necessary to weld large parts. The rectilinear robot's "X," “YP and "Z’ axes move the six-axis articulated robots into, various positions along the weldment. A positioner on elther side rotates the assembly. The axes of rotation can be referred to by name, by number, by letter, or by a similar part of the human body. See Figure 26-15. The various axes and their functions on a six-axis robot are as follows: 1, Waist rotation (rotation around vertical axis) 2. Shoulder bend (rotation about the horizontal axis, provides horizontal reach), 3. Elbow bend (a second rotation about the horizontal axis, provides vertical reach) 4. Arm roll (rotation. 5. Wrist pitch (up and down rotation). 6 Wrist ral (rotation of the tool, torch, or giin) Each axis or joint must have its own mechanism to allow it to move. An electric robot must have an electric actuator (motor) for each axis. The motors for the waist, shoulder, and elbow are tually larger than the motors used to move the arm and the wrist pitch and roll axes. As stated earlier, some robots have more than six axes. A servo resistance welding gun added to a sixaxis robot is an example of a seventh axis. See Figure 26-9, The six-axis robot moves the welding gun into position. The seventh axis closes the welding gun electrodes on the desired spot weld location. Once all seven axes are in the proper position, a signal is sentFigure 26-15. A six-axis robot showing the names assigned to the axes and their motions. to the resistance welding equipment. The resistance ‘welding equipment makes a spot weld. After the spot weld is completed, which takes less than one second, the seventh axis opens the welding gun electrodes. The first six axes of the robot then move the welding gun to the next location and the process repeats. Robots are powerful and move very fast. Workers should never ontor the robot workcell, expocially the robot's working volume, while it is operating. The robot moves so rapidly and with such great force that it can cause serious injury. Fences and barriers are set up around a robot's working area. Safety devices including light curtains, safety mats, and lockout/ tagout entry points are used to keep workers safe. 26.4.3 Robot Controller A robot controller controls the entire robotic system. It is the “brains” of the operation. The main part of the robot controller tsa computer. Every part of the robotic system is connected to this computer. In addition to controlling the operation of the system, the computer monitors all system parts to make sure everything is running properly. Chapter 26. Automatic and Robotic Welding 687 The robot controller performs the following func- tions in the robotic system: + Stores and executes ‘programs to be performed, + Controls and monitors the safety interlocks around the robot workcell # Controls the clamping of an automated fixture and uses sensors to verify that the parts are in the fixture. + Tums the shielding gas on and off and monitors its flow. * Verifies that the cooling water is on and monitors its flow. + Controls and monitors the movement of the robot and the speed and path of the tool, torch, or gun * Controls and monitors the variables required for the welding, cutting, or surfacing process to be used. * Controls the movements of the material handling equipment, if used + Communicates with other robotain the area to prevent one robot from interfering with another. The robot controller uses feedback from sensors to monitor the robotic system. Checks are constantly being made. The sensors involved and the checks made include the following: + Motor torque sensors s0 robot motors are not overloaded + Shock sensors to stop the robot if itimpacts another object. + Thermal sensors so motors and welding exquipuient do not overheat + Flow sensors to make sure cooling wateris flowing, + Arc monitoring sensors to verify that the are starts and continues. If something is not operating properly, the robot will stop and a fault light will turn on. This light indi- cates to the robot operator, welding technician, or maintenance technician that the robot has a problem A fault code is displayed on the robot teach pendant. The fault code identifies what faulted and caused the uperativis te slop, Thre probleut inst be corsected and the fault cleared before restarting the robot Outputs are used to communicate or give com- mands to various pieces of equipment. Inputs are received that confirm the various pieces of equipment are functioning properly. If the correct input is not received, a fault condition exists. These outputs and inputs are what allow a robot controller to control and ‘monitor the automatic equipment.688 Modern Welding A program is a series of operations. The most important function of the robot controller isto execute the program. Through the series of operations defined in the program, the robotic system performs the weld- ing operation. During a complete welding program, the following functions may be monitored or per- formed by the controller: 1, The material handling equipment, or a worker, places the materials into fixtures on the positioner. 2. The controller electronically verifies that parts are loaded votrectly and clamps are in their closed positions, 3. The positioner moves the fixtured pieces into the robot's working volume. 4. With the water flowing and the welding power source turned on, shielding gas flow is started. 5. The weld is started. The welding speed, wire food, and all othor variablos aro controlled and monitored as the robot moves the welding gun or torch along the weld joint 6. With a flexible robotic welding system, feedback devices send signals to the controller so corrections for joint fit-up or location can be made as necessary. 7. When the welding is completed, the shielding gasis shut off 8. When all operations in the program are complete, the positioner moves the welded part out of the robot's working volume Clampe are released ‘The welded assembly is removed, completing one set of operations. During the weld, the controller may shut down the welding operation if the water or shielding, gas stops flowing, arc failure occurs, or if someone enters the robor’s working volume. As it executes the program, the robot controller sends small electrical signals to parts of the system that must be controlled. These output signals control solenoid-operated valves and relays. To control a robot's motions, the controller sends current (output) to the electric motors as needed to properly position the robot. The controller uses feed- back (input) from sensors to verify the robot is in the desired position. This is an example of outputs and inputs used by a robot controller. To move the robot to a new location, the control- ler gives a signal for one or more motors to move in a given direction and speed. Motors begin to move the robot. Information is sent to the controller by a sensor on each motor. The sensor tells the controller the posi- tion of that axis of the robot. The controller compazes tho information from the sonsar to the position the robot should be in, according to the program. Robot motion stops when the data from the sensors matches the data in the program, signifying the robot is in pro- grammed position. No motor or robot ean go from a stopped posi- tion to full speed motion immediately or come to a complete stop from a high rate of motion immediately. A robot is programmed to accelerate and deceler- ate at some value. When directed to move, the robot starts from zero motion and rapidly increases speed or accelorates to the programmed rate af mation. As it nears the end of its programmed move, the robot slows down or decelerates until it reaches its final point, at which time it comes to a complete stop. 26.4.4 Automatic Welding Equipment Automatic welding equipment used in robotic weld- ing is connected to the robot controller. ‘The robot controller operates the entire robotic system, This includes the welding equipment. For resistance spot welding, the controller is pro- grammed to select a welding schedule and force. ‘The resistance welding schedule, which consists of squeeze time, weld time, weld current, hold time, and other variables, is programmed into the welding ‘equipment. When the cycle start button is pressed, the robot moves the welding gun to the correct location. ‘The electrodes come together with the correct pres- sure, The welding equipment ewacutes the resistance welding schedule and the weld is made. If the correct programmed tolerances are achieved, a signal is initi- ated to indicate the weld is complete. After receiving the signal indicating the weld is complete, the robot controller moves the resistance welding gun to a new location. A welding schedule is performed at this loca- tion and another weld is made. This process continues the program in the robot controller is complete all welds have been made ‘Whenaweld ismade with gas metal arc equipment, the controller sends signals to the welding equipment to select a wekling schedule. A welding schedule con- tains the desired welding voltage and wire feed speed to match the robot’s weld travel speed. The controller starts the shielding gas flow. Relays close, and the wire feed and welding begin. The welding equipment deliv- crs the voltage and wire feed in the welding schedule. ‘The robot controller directs the robot to move the weld- ing gunalong the seam to be welded. The robot moves toeach location in the program, and the welding equip- ment executes the required welding schedule. This pro- cess continues until the program in the robot controller is complote and all weldshave heen made ancAutomatic welding equipment that is a part of a robot welding process is exactly the same equipment used in manual and semiautomatic welding. How: ever, for robotic welding, the welding gun or torch mounted on a robot arm. A controller sets and moni- tors all the welding variables. The controler must turn the shielding gas on and off, start and stop the welding process accord- ing to the program, and move the welding gun to the programmed locations on the parts being welded. The controller should aleo be able to con- trol and monitor the wire feed, power source, and the travel speed of the welding gun or torch. Some robots with feedback sensors can even change the welding variables as required to meet changes in the welding joint alignment, Arc welding power sources used with robotics systems must be able to operate at a nearly 100% duty cycle. 26.4.5 Welding Positioners A welding positioner holds the assembly of parts to be welded and moves that assembly into the best welding position possible within the working volume of the robot. Parts are normally clamped into fixtures on a positioner. When clamped into fixtures, the parts are held in a predetermined fixed position A positioner allows the robot to reach all areas, of a part, When a large assembly is placed on a posi- tions, part of the assembly may be outside the rabot’= ‘working volume, Welds can be made only on the weld joints that are within the robot's working volume. ‘When those welds are complete, the positioner then moves the assembly so different arcas are inside the working volume and more welds can be completed. The assembly is continually moved until all welds are completed. The robot's working volume can effe tively be increased by using a positioner. If welds must be made on the top and bottom of an assembly, the positioner can rotate the assembly so each weld can be welded in the flat welding posi- tion. Another option 1s to use a robot as a positioner, Figure 26-16, Positioners are available that can hold two or more parts to be welded. When one part is being welded, a second assembly can be placed in the fixture on the positioner. After the robot completes welding one part orassembly, the positioner moves the second part into the robot's working volume. The completed weld- ment is removed from the fixture, and new parts are installed into the fixture to await welding. Through the use of a two-station welding positioner, the robot can weld with greater productivity See Figitee 26-17 Figure 26-18. The robot on the rights being used as a positioner to move the waldment around. This allows the {wo welding robots on the left to access all areas to be welded. Perimeter fencing Figure 26-17, A GMAW robot workcell, Two fixtures allow the robot ta weld on one assembly while a aceond ene ia being unloaded and loaded. Notice the safety fencing and {guards that prevent the operator from entering the robot work area. When a two-station rotating positioner is used, a metal screen is normally mounted between the two stations, This screen protects the operator, who is on the other side of the screen from the welding opera- tion, while parts are loaded and unloaded from the fixtures890 Modern Welding Positioners usually have two axes about which they rotate. Some positioners have as many as five axes. A positioner is not a required part of a robotic system. Positioners are, however, common in high-production robotic workcells, 26.4.6 Operator Controls The person initiating a robot's operation uses the oper- ator’s control panel to begin the robot program and to tum off the robot in an emergency. An operator's con- trol panel is usually used when an operator is required to load and unload parts. When a robot completes the welding operation on one part, the robot arm and attached welding equipment move back out of the way. It will not move from this “home” position until the welding operator pushes the “cycle start” button. While the robot arm and the attached welding equipment aro out of tho way, the woldment that was just wekled is removed from the welding fixture. New parts are placed in the welding fixture. The operator then presses the cycle start button on the operator's control panel. When the cycle start button is pressed, the robot performs the complete welding operation. When the robot finishes welding, the robot arm and welding torch or gun and positioning equipment again move to their home position and wait for the cycle start button to be pressed again. If something goes wrong during the operation of the robotic system, the operator can stop the process. An “emergency stop” button ison the operator's control panel. To interrupt the program, this button is pressed. Not all robotic systems use an operator's control panel. Some systems have the emergency stop and cycle start buttons on the robot controller. An opera- tor’s control panel is shown in Figure 26-18. 26.4.7 Programming the Robotic System The robot controller stores the sequence of steps and functions that the robot will perform, This sequence of steps and functions is stored in a computer as a pro- gram. Before the controller can store a program, the controller must be taught each step and function in the program. This procesa is called progmmining the robotic system. ‘When teaching or programming the robotic sys- tem, the welding operator uses a teach pendant. See Figure 26-19, The wach pendant has control over each axis of the robot and each axis of the positioner (if used). The welding operator can move the robot using the teach pendant. The robotic controller records the movements and saves them in a program. stop SAB rang a Cureg Paouers Figure 26-18. A positioner with two rotating tables separated by a solid metal screen. The screen protects the operator at the control panel from viewing the are and from. ‘metal spatter. An operator can stop the robotic operation by pressing the emergency stop button. Figure 26-19. A teach pendant used to program a six-axis robotAnother way to program a robot is to use com- puter programming, Robot manufacturers offer soft ‘ware that allows a person to program a robot from a computer. See Figure 26-20, The robot is programmed offline, away from the actual robot and without mov- ing the actual robot. Offline programming allows a company to create new programs while the company’s robots continue manufacturing parts using existing programs. When a new program is ready, it can be quickly uploaded to the robot controller. Once the new program is uploaded, the mbots resume manufactur. ing using the new program. Since robot downtime is minimized, productivity is maximized. ‘A programmer must create an accurate computer model of the patts being welded, fixtures being used, a positioner if used, and all obstructions in the work. cell. Each movement of the robot can then be pro- grammed. All motions and potential interfere can be checked. When programming ts complete, the program is uploaded from the computer into the robot controller's memory. ‘There are many steps and functions within one pro- g1am. The following are some of the more important steps and functions: + The movements or path of the robot, + The speed of the robot's movement. * When and where to begin the welding sequence: ‘+ When and where to stop the welding sequence. ‘+ The welding variables + Motion type of robot movements (joint, linear, and circular) Figure 26-20. Programming a welding robot on a computer. Offline programming permits production robots to keep working. Chapter 26 Automatic and Robotic Welding 691 ‘One of the most important parts of a program is, the movement of the robot. All programs must have a pointin space from which they can measure the move- ments of the robotand the tip of the welding electrode. This point in space is called the set-up point. yu. ‘The set-up point is also known by other names, such as the zero point or home point. A tool called the set-up jig is used in the robotic ‘workcell tolocate a predetermined point in space—the set-up point. A specific point on the robot arm is then aligned with the set-up point. After this alignment is completed, the robot and welding torch or gun can be moved through the required welding sequence and the program placed into memory. All robot movement is measured by the computer from the set-up point. To program the motion of the robot, a series of loca- tions or points are taught. When the program is run, tho robot moves dirvetly from one point to the next. A robot moves to get from point to point in certain ways. The main motion types of robotic movement are joint, linear, and circular. A joint move is a motion type in which the robot uses one or more axes to move the welding gun from point to point as fast as possible. This move type is generally used for moving in an open area where Elearance is not an issue. A linear move is a motion type in which the robot moves the welding gun from point to pointin astraight line. The robot keeps the welding gun in the same ori- entation. The robot uses multiple axes to produce a lin- ear move. Welding a straight fillet weld with GMAW is an example of using a linear move. The travel and ‘work angle must be maintained while welding the fil let weld. Multiple axes must move to maintain a linear motion of the welding gun. ‘A circular move is a motion type used when the robot is required to move the welding gun around an object, such as a pipe, but maintain a path tracking around the circle. This motion type could be used for welding a pipe to pipe, or pipe to a plate. When programming a robot with a teach pendant, the welding operator uses the teach pendant to move the robot to a desired location. After the new location is reached, a “teach” or “add” button is pressed. This point becomes one point in the program. The welding operator then moves the robot to the next point in the program. Again, the “teach” button is pressed. This process is continued until the robot's movements for a complete cycle or sequence of actions are completed882 Modern Welding Sometimes it may be necessary to delete a point in a program. This process is similar to the way a point is added. The robot is moved to the point to be removed, and the “delete” button is pressed. That point is no longer a part of the program. ‘An example of point-to-point movement is shown, in Figure 26-21. A robot operator wants to move the welding torch on the end of the robot arm from point 1 to point 4. Four points may be programmed, so the robot’s movements will miss the obstacle between points 1 and 4. The robot maves from point 1 to point 2, from point 2 to point 3, and then from point 3 to point 4. Each movement will be a straight line. If the robot operator decides to delete point 2, the robot moves from paint 1 to point3,and then to point 4 This movement is faster than moving from 1 to 2 to3 to4. The obstacle is still missed. If point 3 were deleted, however, the robot would attempt to move directly from point 1 w point 4. During this movernent, the ‘welding torch on the robot arm would hit the obstacle The welding torch might be damaged. The robot might also require maintenance after such a collision. Ifa robot or the welding torch hits something, as it travels in the workcell, an emergency stop sensor or “shock sensor” will shut down the robotic system. After a collision, the robot must be realigned with the setup point. Another important function that must be pro- grammed is the speed at which the robot moves Speeds can be relatively slow, such as welding speeds of 10 in/min to 30 in/min 4 mm/sec to 13 mm/sed. Maximum speeds depend on the robot being used. Speeds can exceed 3500 in/min (1500 mm/sec) Fach painktopnint mavemont can he made at a different speed. When a robot is moving through open areas away from any obstacles, travel speeds canbe very high. When the robot moves toward the workpiece, or roar an obstacle, the travel apoed ie ucually reduced. The travel speed can be reduced in steps. See Figure 26-22 : ¥ sl 1 ae Gocdthenr leas Pubs Figure 26-21. Pontto-paint movement. To move a robot trom point to point 4, two paths can be folowed. Either the path 1-234 or the path 1-3-4 can be used. The robol cannot move directly trom point | lo pon, ort wl hit the obstacle infmin | mmisec 2860 1200 3550 1500 2850 1200 1420 500, Figure 26 22. Robot opoods used to go from point 1 to point 5. Note the speed is faster from point 3 to point 4 than from point 4 to point 6. Ihe movement from point 3 to point > could all be done at 1420 in/min (600 mm/sec). One way to speed up the robot program is to use different speeds in each step. Moving from point 3 to point 4 can be done at 2850 in /min (1200 mm/sec), which requires less time. Reducing the travel speed in steps allows a faster speed to be used for all but the last few inches (1 limeters) of travel For the robotic system to know when to begin weld- ing, it must be programmed. In addition to knowing when to weld, the controller must be programmed to tum on the shielding gas and wire foeder (whon teed) The controller must set the current, weld sequence times, weld travel speed (GMAW), and electrode force in resistance welding, Each of these operations is a ctep in the program. A typical set of functions required to begin GMAW is as follows: 1. Set the voltage and wire feed speed. Welding parameters are set by entering the values while programming the robot. 2. Turn on the shielding gas. 3. Adda delay function for 0.5 seconds to allow the shielding gas to cover the welding area before the ‘weld begins. 4, Begin feeding electrode wire 5. Add another delay function of 0.5 seconds. This allows the arc to stabilize and a proper-sized molten pool to develop. 6. The robot begins moving along the joint tobe welded.A similar set of functions is required to stop weld- ing and for the robot to return to its home position. ‘Time may also be programmed to allow the positioner to be rotated and the part unloaded before the weld cycle begins again. Welding parameters are usually set using the teach pendant. ‘A robotic system has two modes of operation— manual and automatic. All programming is done in the manual mode. Any change to the robot's move- ments or change in the welding parameters is done in the manual mode. Toexecute the program, the robotic system is placed in automatic mode. The robotic system is then com- pletely automatic. It will perform the program exactly. The program can be repeated over and over 26.4.8 Robotic System Opei When the prugraiuning of « robotic syste pleted, it ean be used to perform the desired welding operations. Before making any welds, the welding operator should inspect the robotic system for the following: * Check that all safety equipment is in place. ‘* Check that all equipment has power and is ready to operate. * Check that the desired program is selected and is ready to execute. * Check that the shielding gas cylinder (if used) 48 open and contains gas. ‘+ Check to see if the electrode wire spool (if used) has wire ‘+ Check all electrical connections ‘+ Check the cooling water lines (if used) for leaks. ‘+ Check that the welding equipment is in good condition and ready t operate. In addition to checking the equipment, the welding, operator should check that the following are correct: + Shielding gas. + Blectrode wire composition. lectrode diameter Finally, the robot operator places the parts to be welded in thei proper place. This usually involves placing the parts ina fixture. See Figure 26-23. ‘The robotic system must be in the automatic mode. To begin the program, the cycle start button is pressed. The robot controller directs the robotic sys- tem through the program steps. Remember that all parts of the robotic system—the robot, the positioner, and the automatic welding equipment—are controlled by the controller. Chapter 26. Automatic and Robotic Welding 693 Toggle clamp Pe Fore Figure 26-23. A multipart fixture. Three parts are loaded. The robot is equipped with a GMAW gun. When a robotic system has completed a program, the robot arm moves back to its home position. The sys- tem will not move until the cycle start button is pressed again or a sensor tells the controller that everything is ready to weld the next part. Never let any part of yout body be near a moving welding torch, robot, or wipment. “T Never enter the robot's wodking volume when the robot is operating. To prevent entry into the robot ‘workcell, install fencing, safety mats, or an electronic barrier. Sensors may be mounted on the fencing, If anyone enters the workcell, the sensors or electronic barrier causes the robotic system to shut down. 26.4.9 Comparing Robotic Systems Many manufacturers produce different robots designed for different purposes, Industry uses many of these roborson assembly lines. See Figure 26-24. Not all robots are made for welding, however, Before any robotic system is purchased, the manu facturer should be consulted. Each robotic system has advantages and disadvantages. Kobots are available in different sizes, working volumes, payloads, reaches, speeds, and number of axes. An important consideration is robot accuracy, which isalso called repeatability. Robot accuracy is the ability of robot to go from one point to another point exactly. There is always some chance of error involved. The robot ‘may not go exactly to the programmed point. but will be very close. A welding robot usually has an accuracy694 Modern Welding Figure 26-24. A number of robots equipped with resistance spot welding guns are welding car bodies on an assembly tne, (repeatability) of 40.004” (0.10 mm) or Jess. This means that the robot will move to within 0001” 10 mm) of the programmed point during every repeated cycle. Some robots have greater accuracy than others 26.5 Safety Practices in Automatic and Robotic Welding All of the safety practices discussed in previous chapters relative to GMAW, GTAW, resistance weld- ing, cutting processes, and related topics also apply to automatic and robotic welding and cutting. pro- cesses. Be lert around powe Some type of safety barrier must be placed around the robot workcell to prevent entry. Safety barriors include mechanical fencing, electric light curtains, pressure-sensitive safety mats, laser scanners, and safety locks. These are used to keep operators saleand prevent ent ing or have the ability to move Always check the electrical leads and gas hoses so they do not get caught during the operation of auto- matic equipment or fobors. Before operating a system at full speed, execute the program (sequence of moves) at slow speeds. During this test run, any interference of cables or hoses can be seen and corrected. If automatic welding equipment or a rob: tem is not functioning properly, press the “emergency stop” button. Do not attempt to fix the equipment while itis operating. An automatic machine or robot hasa lot more power and strength than a person into a robot cell when robots are work=Summary + Automatic welding is done with equipment that requires only occasional or no observation of the welding and no manual adjustment of the equipment controls. + A robot isa programmable machine that can ‘move material or tools through a set of motions to accomplish a desired task. + In robotic welding, the robot holds the welding ‘gun and moves it along or around the weld joint. + The advantages of automatic welding are increased productivity, improved weld quality, reliability, flexibility, and reduced cost. + Anautomatic welding machine or robot relies on feedback provided in the form of electrical signals to determine if everything is working properly. + In welding applications, flow switches are used to ‘monitor the flow of air, shielding gas, and water. + A-solenoid-operated valve starts and stops the flow ofa gas or liquid + Axelay is used to start and stop the flow of electrical current + Electrical actuators, which are electric motors, are used to move and position the various parts of a robot about their rotational axes. Common motor types are servomotors, stepper motors, and permanent magnet DC motors. + Semiautomatic welding is manual welding done with equipment that automatically controls one or more of the welding conditions + AWS defines mechanized welding ae “welding with equipment that requires manual adjustment of the equipment controls in response to visual observation of the welding, with the torch, gun, or slecttoxie hokler held by a mechanical device.” + The robotic system includes the equipment and software needed to accomplish the welding, cutting, or surfacing task, + There are two common systems of robot motion. An articulated robot rotates around various axes, usually six axes. A rectilinear robot moves in straight lines in the “X.” “Y." and “Z” axes. + The robot controller sets and monitors welding, variables and uses electrical commands or signals to perform the sequence of operations called the program. + A welding positioner holds the assembly of parts tobe welded and moves that assembly into the best welding position possible within the working volume of the robot. * The operator's control panel is used to begin the robot program and to shut down the robot in an. emergency! + Before the controller can store a program, the robotic system must be programmed. The system can be programmed with a teach pendant or by offline programming, * A robot moves to get from point to point by joint, linear, or circular motion. # Nesane chonld ontor a eahot workcell or wnseking, volume when the robot is operating. Fencing or a safety light curtain is placed around the robot ‘workcell to prevent entry. Technical Terms Saloct the icone to accone Drill and Practice activitica articulated robot rectilinear robot automatic mode repeatability. automatic welding semiautomatic welding feedback controls servomotor flow switch set-up jig industrial robot set-up point manual mode stepper motor offline programming teach pendant positioner working volume program, Review Questions ‘Fustwer The following questions using tie formation provided in this chapter. Know and Understand 1. Thue or False? Compared to manual SMAW, much, higher currents can be maintained with a given electrode size in automatic GMAW or GTAW. 2. An automatic welding machine receives feedback in the form of A. electrical signals B. laser beams C. magnetic pulses D, mechanized movement 3. In welding applications, flow switches are used to. A. control the welding speed B. monitor the flow of electric current . control the welding wire speed D. monitor the flow of air, shielding gas, and water4, True or False? A solenoid-operated valve starts and stops the flow of electrical current. 5, Manual welding with equipment that automatically controls one or more of the welding conditions is a description of __ welding. A rae B. mechanized . semiautomatic D. manual SMAW 6. The three-dimensional space a robot can reach is called the A. set-up point B. axis ©. workcell D. working volume 7. The wrist pitch of a robot refers to. ‘A. rotation around a vertical axis B. up and down rotation , rotation of the torch or gun D. the ability of a robot to toss an object 8. What part of the robot system controls the operation of the system and monitors system parts to ensure that everything is running properly? A. Three-way solenoid-operated valve. B. Stepper motor. ©. Robot controller 1D. Teach pendant 9, True or False? linear move is a motion type in Which the robot uses one or more axes to move the welding gun from point to point as fast as possible. 10. True or False? The term repeatability refers to the ability of a robot to go from one point to another point exactly. Apply and Analyze 1, What is the advantage of using a relay? 2, Name the three types of electric motors normally used to move a robot around its axis. 3. What is the difference between mechanized welding and automatic welding? 4, Name three variables used in a resistance welding schedule. 5, In general, how do inputs and outputs allow a robot controller to control and monitor the automatic equipment? 6. Are welding power sources used with robotics systems should operate at what duty cycle? 7. What is the function of a welding po: ‘What does it mean to program a robot offline? 9. What should be done to prevent people from entering the working volume of a robot while itis in operation? 10. Why should the program be executed at slow speeds before the robotic system is operated at full speed? Critical Thinking 1. Two or more robots are moving in the same area. Describe one method to prevent the robots from colliding with each other. 2, Use the Intemet and identify two careers involved with robotics, Experiment 1, With access to a robot, create a simple program with two steps. Move the robot and program one location, point 1, on the left side of the robot's working volume. Use a joint move step to move toa second location, point 2, toward the right side of the robot’s working volume. Run the program and allow the robot to move from point 1 to point 2. Observe the path of the robot farm and tool as it moves from point 1 to point 2. Keeping the same two programmed locations, change the move type from a joint move to a linear move. Run the program again from point 1 to point 2and observe the path of the robot arm. and tool, What is different and why? onmGoodheat Wkon Co,4, True or False? A solenoid-operated valve starts and stops the flow of electrical current. 5, Manual welding with equipment that automatically controls one or more of the welding conditions is a description of __ welding. A rae B. mechanized . semiautomatic D. manual SMAW 6. The three-dimensional space a robot can reach is called the A. set-up point B. axis ©. workcell D. working volume 7. The wrist pitch of a robot refers to. ‘A. rotation around a vertical axis B. up and down rotation , rotation of the torch or gun D. the ability of a robot to toss an object 8. What part of the robot system controls the operation of the system and monitors system parts to ensure that everything is running properly? A. Three-way solenoid-operated valve. B. Stepper motor. ©. Robot controller 1D. Teach pendant 9, True or False? linear move is a motion type in Which the robot uses one or more axes to move the welding gun from point to point as fast as possible. 10. True or False? The term repeatability refers to the ability of a robot to go from one point to another point exactly. Apply and Analyze 1, What is the advantage of using a relay? 2, Name the three types of electric motors normally used to move a robot around its axis. 3. What is the difference between mechanized welding and automatic welding? 4, Name three variables used in a resistance welding schedule. 5, In general, how do inputs and outputs allow a robot controller to control and monitor the automatic equipment? 6. Are welding power sources used with robotics systems should operate at what duty cycle? 7. What is the function of a welding po: ‘What does it mean to program a robot offline? 9. What should be done to prevent people from entering the working volume of a robot while itis in operation? 10. Why should the program be executed at slow speeds before the robotic system is operated at full speed? Critical Thinking 1. Two or more robots are moving in the same area. Describe one method to prevent the robots from colliding with each other. 2, Use the Intemet and identify two careers involved with robotics, Experiment 1, With access to a robot, create a simple program with two steps. Move the robot and program one location, point 1, on the left side of the robot's working volume. Use a joint move step to move toa second location, point 2, toward the right side of the robot’s working volume. Run the program and allow the robot to move from point 1 to point 2. Observe the path of the robot farm and tool as it moves from point 1 to point 2. Keeping the same two programmed locations, change the move type from a joint move to a linear move. Run the program again from point 1 to point 2and observe the path of the robot arm. and tool, What is different and why?