With the development of science and technology, welding processes are constantly innovated and optimized. One of the important trends is the use of automated robots to achieve efficient, precise and stable welding. So, what are the automated robot welding methods? This article will introduce the advantages of automated robot welding, the classification of automated robot welding, technical points of automated robot welding, and application cases of automated robot welding.
1. Advantages of automated robotic welding
Compared with traditional manual welding, automated robot welding has the following significant advantages:
1) Improve welding quality and consistency.
The automated robot can accurately control the welding current, voltage, speed, angle, trajectory, etc. according to the preset programs and parameters, thereby ensuring that the shape, depth, strength and appearance of each weld achieve the desired effect, avoiding manual welding Possible deviations, defects and errors.
2) Improve production efficiency and reduce costs.
Automated welding robots can perform welding operations in a high-speed, continuous and stable state, greatly shortening the welding time and improving production efficiency. At the same time, automated robots can also save the consumption of manpower, materials and energy, and reduce production costs.
3) Reduce workers’ labour intensity and risks.
Automated robots can weld in harmful, dangerous or complex environments, such as high temperature, high pressure, high altitude, high radiation, high dust, etc., thereby reducing workers’ labour intensity and risks, and ensuring workers’ health and safety.
4) Improve product innovation and competitiveness.
Automated robots can flexibly switch and combine a variety of welding processes and methods to adapt to the welding needs of different materials, structures and shapes, thereby increasing product innovation and competitiveness.
2. Classification of automated welding robots
According to different welding processes and methods, automated robot welding can be divided into the following types:
1) Arc welding robot.
Arc welding is a welding method that uses the high temperature generated by the arc to melt the materials to be welded and the welding wire. Common ones include gas-shielded welding (such as CO2 welding, MIG welding, TIG welding, etc.), submerged arc welding, plasma welding, etc. Arc welding robots can be used for welding various metal materials, especially steel, aluminium, copper, etc. An arc welding robot usually consists of a robot body, a control system, a welding power source, a welding gun, a wire feeder, a protective gas system, etc. It has six or more degrees of freedom and can achieve welding with complex spatial trajectories and postures.
2) Laser welding robot.
Laser welding is a welding method that uses the high energy density generated by a laser beam to melt the material to be welded. Common ones include laser deep penetration welding, laser heat conduction welding, laser brazing, etc. Laser welding robots can be used to weld various metal and non-metal materials, especially materials with high strength, high hardness, and high melting point, such as titanium alloys, nickel-based alloys, ceramics, etc. Laser welding robots usually consist of a robot body, a control system, a laser, an optical fibre, a focusing mirror, a protective gas system, etc. It has the characteristics of high speed, high precision, high quality, low deformation, and low pollution.
3) Spot welding robot.
Spot welding is a welding method that uses the principle of resistance welding to simultaneously heat, melt and press two or more metal workpieces at one or more points. Common ones include AC spot welding, DC spot welding, pulse spot welding, etc. Spot welding robots are mainly used in the welding of thin metal sheets in the automotive, home appliances, electronics and other industries, especially steel, stainless steel, aluminium, etc. Spot welding robots usually consist of a robot body, a control system, a welding clamp, a welding power supply, a cooling water system, etc. It has the characteristics of high efficiency, stability, energy saving, and environmental protection.
3. Technical key points of automated robot welding
1) Selection and optimization of the welding process.
According to different materials, structures, shapes, properties and requirements, select appropriate welding processes and methods, and determine reasonable welding parameters, such as current, voltage, speed, angle, trajectory, protective gas, etc., to ensure welding quality and efficiency.
2) Selection and configuration of a welding robot.
According to different welding processes and methods, select the appropriate welding robot type and configure the corresponding welding equipment and systems, such as welding power supply, welding gun, wire feeder, laser, optical fibre, welding tongs, etc., to ensure the function and performance of the welding robot.
3) Programming and debugging of welding robots.
According to different welding workpieces and tasks, write appropriate welding robot programs, set the motion trajectory and posture of the welding robot, and various welding parameters, and debug and optimize the welding robot through teaching, offline programming, simulation, etc., to ensure the accuracy and stability of the welding robot.
4) Monitoring and control of welding robots.
According to different welding processes and methods, corresponding sensors and controllers are used to monitor and control the operating status and welding quality of the welding robot in real-time, such as welding seam tracking, welding arc stabilization, welding temperature control, welding defect detection, etc. To ensure the reliability and safety of welding robots.
4. Application cases of automated robot welding
Automated robot welding has been widely used in various industries and fields. Here are some typical application cases:
1) Automobile industry.
The automotive industry is the largest and earliest application field of automated robot welding. Almost all automotive parts require welding, such as body, chassis, engine, gearbox, exhaust pipe, etc. Automated robot welding can improve the quality, efficiency and safety of automobiles, and reduce the cost and pollution of automobiles. At present, the automotive industry mainly uses arc welding robots and spot welding robots, as well as some laser welding robots and other types of welding robots. For example, the bodies of Tesla’s Model 3 and Model Y use laser welding robots to achieve high-strength, high-precision and high-speed welding.
2) Aerospace industry.
The aerospace industry is the most high-end and advanced application field for automated robot welding, involving the welding of various complex structures and materials, such as aircraft, rockets, satellites, space stations, etc. Automated robot welding can meet the high quality, high reliability and high-performance requirements of the aerospace industry, and can also adapt to the special environments and conditions of the aerospace industry, such as high temperature, high pressure, high altitude, high radiation, etc. Currently, the aerospace industry mainly uses laser welding robots and arc welding robots, as well as some other types of welding robots. For example, the return capsule of China’s Shenzhou 12 manned spacecraft used a laser welding robot to achieve high-strength, high-sealing and high-safety welding.
3) Other industries.
In addition to the automotive and aerospace industries, automated robot welding is also used in various other industries and fields, such as construction, shipbuilding, home appliances, electronics, machinery, energy, medical, etc. Automated robot welding can select and optimize different welding processes and methods according to the characteristics and needs of different industries and fields to achieve different welding purposes and effects. For example, Japan’s Tokyo Olympics torch uses arc welding robots to achieve high-looking, high-durability and high-environmentally friendly welding.
In short, automated robot welding is an efficient, accurate and stable method of using automated robots to achieve welding. It has many advantages and characteristics. It has been widely used in various industries and fields and has also demonstrated a lot of innovation and competition. force. The technical points of automated robot welding mainly include the selection and optimization of welding processes, the selection and configuration of welding robots, the programming and debugging of welding robots, the monitoring and control of welding robots, etc., which require continuous research and development to adapt to the changing welding conditions. needs and challenges. Automated robot welding is an important development direction of welding technology and is also the future trend of welding technology.