Welding, often referred to as the "tailor" of industry, is a crucial and common processing method in industrial production. However, due to harsh working environments that seriously endanger worker health, increasingly stringent market demands for quality, and a growing need for cost reduction and efficiency improvement, the supply-demand imbalance in traditional welding has become increasingly prominent. Industrial robots have thus entered the world of welding, replacing manual welding processes in various industries. Robotic welding is gradually becoming a new welding method in workshops, not only improving work efficiency but also enabling mass production.
Welding applications are widely recognized as a "tough nut to crack" in the robotics industry. Practical application requires overcoming not only technical barriers in hardware and software incompatibility, but also resolving challenges such as non-standard and uncertain workpieces. Furthermore, there are challenges related to large and complex workpieces, special materials, unique shapes, and process stability, all of which require individual breakthroughs.
I. Working Principle of Laser Welding Robot
The semiconductor laser soldering robot system is equipped with a position correction system to ensure the accuracy of solder joint positions and the optimization of process parameters. Its principle is to illuminate marked points on the workpiece using a camera, and then use a high-performance image processing device and a laser displacement sensor to correct the soldering position and height.
Process parameters such as output power, laser irradiation time, and welding temperature profile can be set via an LCD touchscreen.
The laser head is equipped with an anti-smoke optical lens and protection system; maintenance only requires replacing the protective glass at the front of the lens. A compact, high-power laser generator within the system allows selection of a laser beam with a suitable spot size. The laser power is available in two maximum levels: 30W and 50W (air-cooled), and is continuously adjustable to achieve optimal welding power.
II. Characteristics of Laser Welding Robots
1. It is non-contact, with the smallest laser dot diameter as small as 0.1mm and the smallest solder feeding device as small as 0.2mm, enabling the soldering of micro-pitch packaged (mounted) components.
2. Because it is a short-term localized heating, the thermal impact on the substrate and surrounding components is minimal, resulting in good solder joint quality.
3. No soldering tip consumption, no need to replace heater, and high work efficiency during continuous operation.
4. When performing lead-free soldering, solder joint cracks are less likely to occur.
5. The surface temperature of the solder should be measured using a non-contact method, rather than a method that actually contacts the solder head.
III. Functions of Welding Robots:
1. Automatic positioning function. The welding robot's welding torch can weld workpieces with different structures. Based on the specifications of the weld, the control system can issue instructions to drop just the right amount of welding material to fill the weld, improving welding accuracy and achieving stable welding.
2. Memory function. During the debugging process, the operator can first perform a pre-welding operation by manually controlling the welding robot. The welding robot will store and save this series of actions, so that welding activities can be carried out according to the motion trajectory. In addition, the welding robot can store a certain amount of programming data, which can be recalled during the next welding operation.
3. Self-protection function. In case of worker misoperation or malfunction of the welding robot itself, the welding robot can send an alarm signal through sensors, allowing the operator to immediately stop the operation and protect the welding robot from damage. The sensors can also monitor the welding quality in real time, helping to stabilize the welding quality.
4. Multi-layer, multi-pass welding function. When welding thicker workpieces, a multi-layer, multi-pass welding method is usually adopted. During welding, the welding path stored by the sensor is slightly offset, and multiple layers of welding can be repeated. The multi-layer welding function only needs to repeat the welding once, and the remaining weld passes can be automatically welded.
IV. How to ensure the welding quality of industrial welding robots
Excellent weld filling. Industrial welding robots perform welding operations through a control system. By intelligently recognizing the weld seam, the control system uses an actuator to automatically position the welding torch at the weld seam and place just the right amount of material to fill the weld, resulting in a strong and aesthetically pleasing weld.
Proper manual maintenance is essential. Industrial welding robots are considered fixed assets of enterprises. If properly maintained, they can last for decades. Routine maintenance includes cleaning the robot's axes, replacing frequently used parts in a timely manner, and updating welding parameters. Good maintenance helps ensure consistent welding quality.
The welding industry has seized the trend of social and economic development and improved its level of automation and intelligence. The difference between industrial welding robots and traditional welding is that they have high production efficiency, low cost, and stable product quality. If enterprises want to improve their market competitiveness, they need to improve welding quality while increasing production speed.
