Robot system failure
1. A collision occurred.
The problem may be due to a deviation in the workpiece assembly or an inaccurate TCP of the welding torch. You can check the assembly or correct the TCP of the welding torch.
2. An arc fault occurs, preventing arc ignition.
The problem may be due to the welding wire not contacting the workpiece or the process parameters being too small. You can manually feed the wire, adjust the distance between the welding torch and the weld, or adjust the process parameters appropriately.
3. Protective gas monitoring and alarm
There is a fault in the supply of cooling water or protective gas. Check the cooling water or protective gas lines.
Common defects in welding robots
1. Problem of weld misalignment occurs
The problem might be due to incorrect welding position or a problem with the welding torch's positioning. In this case, check the accuracy of the TCP (welding torch center point position) and adjust it accordingly. If this happens frequently, check the zero position of each robot axis and recalibrate to correct it.
2. Edge biting problem occurs
The problem may be due to improper selection of welding parameters, incorrect welding torch angle, or incorrect welding torch position. These can be adjusted accordingly.
3. Problems with pores
The problem may be due to poor gas protection, excessively thick primer on the workpiece, or insufficiently dry protective gas. Making the appropriate adjustments will resolve the issue.
4. Excessive splashing problem
The problem may be due to improper selection of welding parameters, gas composition issues, or excessively long welding wire extension. The welding parameters can be changed by adjusting the machine power, adjusting the gas ratio meter to adjust the mixed gas ratio, and adjusting the relative position of the welding torch and the workpiece.
5. Problem of an arc crater forming at the end of the weld after cooling.
When programming, an arc crater function can be added to the working step to fill it.
Programming skills for welding robots
1. Select a reasonable welding sequence to reduce welding deformation and welding torch travel path length.
2. The spatial transition of the welding torch requires a short, smooth, and safe movement trajectory.
3. Optimize welding parameters. In order to obtain the best welding parameters, make working specimens for welding tests and process evaluation.
4. Employ appropriate positioner positioning, welding torch posture, and welding torch-to-joint position. After the workpiece is fixed on the positioner, if the weld seam is not in the ideal position and angle, the positioner must be continuously adjusted during programming to ensure that the weld seam gradually reaches a horizontal position according to the welding sequence. Simultaneously, the positions of each robot axis must be continuously adjusted to reasonably determine the position, angle, and wire extension length of the welding torch-to-joint. Once the workpiece position is determined, the position of the welding torch-to-joint must be observed visually by the programmer, which is quite challenging. This requires programmers to be adept at summarizing and accumulating experience.
5. Insert the torch cleaning program in a timely manner. After writing a welding program of a certain length, the torch cleaning program should be inserted in a timely manner. This can prevent welding spatter from clogging the welding nozzle and contact tip, ensure the cleanliness of the welding torch, improve the life of the nozzle, ensure reliable arc ignition, and reduce welding spatter.
6. Programming is generally not something that can be done in one step. It requires continuous testing and modification during the robot welding process, as well as adjustments to welding parameters and welding torch posture, to create a good program.
A robot is a high-speed moving device, and people must never approach it when it is running automatically (safety railings must be installed).
In addition: Operators must receive specialized training in occupational safety; otherwise, operation is prohibited. Safety first, life paramount! Please pay close attention to safety when using welding robots and six-axis robots! If these factors are not considered during operation and the operation is carried out blindly, incorrect operation methods may affect the welding effect and the overall operation. This is an issue that users must pay attention to before use.
