Robotic-arc-welding,

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Robotic-arc-welding
can be a beneficial move away from constraints that limit expansion of shops already struggling at full capacity, when presented with the opportunity to grab a share of new production orders.

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The introduction of Robotic arc welding, however, should be gradual and well conceived, starting with simple, repetitive jobs, because unsolved difficulties may be overwhelming if the process is not planned adequately

Robotic-arc-welding has known a slow and painful introduction to industry. By now it is quite mature a technology and can be applied successfully, if supported by knowledgeable personnel.

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The welding process adopted is generally the Gas Metal Arc Welding that can be adapted to widely varying conditions, provided it is conducted properly.

According to certain critics, the weak points were at first lack of welding process expertise and incorrect attitudes that prevented management from seeing the real problems and solving them.

One such critic, the world renowned expert Ed Craig, dedicated
Chapter 11, from page 289 to page 434, of his book
"A Management and Engineers Guide to Mig Welding,
Quality-Cost-Training"
to Mig Welding with Robots.
For anyone involved with this subject, this book is a warmly recommended reading for understanding and learning.

Ed Craig
A Management and Engineers Guide to MIG Welding Quality-Costs-Training
Document Number: AWS 050
American Welding Society, 01-Jan-1996
640 pages
Click to Order.

Mechanized and automated processes are built for continuous welding and must be retooled for any major change in the product. They are described as rigid or inflexible processes.

Robotic-arc-welding has in principle the following potential advantages:

• multipurpose, flexible, reprogrammable, permits change from one application to another by switching software,
• suitable for work in hostile environments,
• highly productive, with high weld current, deposition rate and welding speed,
• results repeatable and reliable, with adequate sensors providing real time parameter adjustment,
• freedom from rest time.

The following limitations of Robotic-arc-welding must be considered:

• welding process expertise required from operator,
• robot welding programs must be developed by expert personnel,
• parts must be manufactured and assembled for welding within strict tolerances ,
• fixtures and cells must be designed with competence,
• planned maintenance of equipment and torch must be enforced,
• robot unplanned downtime may be costly.

As a general observation one should note that, owing to increasing difficulties in filling job openings with expert welders, industries are actively driving the move to flexible automatic or robotic welding.

In effect the fact that many companies do not achieve the productivity required from their Robotic-arc-welding systems is attributed, by no less authority than AWS Welding Handbook 9th edition, Volume 1, page 472, "to a lack of qualified personnel". Therefore in the coming years there will be a remarkable increase in robotic welding jobs available to qualified welders.

Robotic arc welding cells need expert operators to run them smoothly and profitably. It may be a tempting challenge for ambitious welders, to learn the various disciplines that combine in this demanding job. It is not easy but good operators will be in demand and will be able to obtain improved wages.

One should note that AWS has recently introduced a new Certification Program for Robotic Arc Welding - Operators and Technicians (CRAW). See
http://www.aws.org/w/s/certification/CRAW/

The following documents can be consulted:

ANSI/AWS D16.1M/D16.1:2004
Specification for Robotic Arc Welding Safety
American Welding Society, 03-Feb-2004
28 pages
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ANSI/AWS D16.2/D16.2M:2001
Guide for Components of Robotic and Automatic Welding Installations
American Welding Society, 30-Nov-2001
26 pages
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ANSI/AWS D16.3M/D16.3:2001
Risk Assessment Guide for Robotic Arc Welding
American Welding Society, 01-Jan-2001
30 pages
Click to Order.

ANSI/AWS D16.4M/D16.4:2005
Specification for the Qualification of Robotic Arc Welding Personnel
American Welding Society, 13-Jul-2005
24 pages
Click to Order.

Robotic Arc Welding systems are defined by their:

• capability of motion and space covered,
• maximum load capacity,
• maximum movement speed,
• accuracy and repeatability.

Potential productivity gains are realized, under correct conditions, by avoiding oversize welding and increasing speed, relative to manual welding.

The easy part of programming is that describing the robot's path to follow. Preferably this part should be performed off-line. The welding part of the program should first be developed and tested for manual welding, and only then adapted (higher current, higher speed) for Robotic-arc-welding.

Ed Craig's book mentioned above is very specific on how best to adjust welding parameters to obtain consistent performance with a properly programmed Robotic-arc-welding process.

Some of his recommendations are summarized in notes published in four issues of Practical Welding Letter, in links available from our page on Mig Welding Tips.

Like every less familiar technology, introduction of a Robotic-arc-welding project requires thorough learning and planning to exploit its intrinsic high productivity potential, providing the best possible Return on Investment.

An Article on Robotic Welding was published (2) in issue 17 of Pactical Welding Letter for January 2005.
Click on PWL#017 to read it. (Opens a new Window).

Looking for more Online Reference Links? Click on Welding Resources

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To reach a Guide to the collection of the most important Articles from Past Issues of Practical Welding Letter, click on Welding Topics.

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Robotic-arc-welding is an application of technology capable of realizing important economic advantages by increasing industrial productivity, if properly implemented, despite the present and future shortage of skilled manual workforce.