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The automatic arc welding robot workstation has seen significant technological advancements, offering numerous benefits. These include enhanced stability and improved welding quality, increased labor productivity, reduced physical strain on workers, and the ability to operate in hazardous environments. It also lowers the technical skill requirements for operators and shortens the product modification preparation time, reducing the need for extensive equipment investment.
Welding robots generally consist of two main components: the robot itself and the welding equipment. The robot includes a robotic arm and a control cabinet (both hardware and software). For welding equipment, such as arc or spot welding systems, they typically involve a power source (with its control system), a wire feeder (for arc welding), and a welding torch or clamp. Intelligent robots may also incorporate sensing systems like laser or camera sensors along with their control mechanisms. Figures 1a and 1b illustrate the basic components of an arc welding robot and a spot welding robot, respectively.
**Key Characteristics of Arc Welding Robots**
(1) **Basic Functionality**
The arc welding process is more complex compared to spot welding. It requires precise control over the tool center point (TCP), the movement path of the wire end, the torch orientation, and various welding parameters. Therefore, arc welding robots must have specific functions tailored for this process beyond general capabilities.
While a five-axis robot can technically be used for arc welding, it is often insufficient for complex welds. Unless the weld is simple, a six-axis robot is usually preferred for better flexibility and precision.
In addition to the standard features shown in Figure 2, arc welding robots should be capable of closely following a "Zigzag" or small-diameter circular welding path. They should also support different swing patterns through software, allowing for programmed swing welding. At each cycle’s pause point, the robot should automatically stop moving forward to meet process requirements. Additional features like contact positioning, automatic weld start detection, arc tracking, and re-ignition are essential for efficient operation.
(2) **Welding Equipment for Arc Welding Robots**
Arc welding robots commonly use gas-shielded welding methods, such as MAG, MIG, and TIG. They can be equipped with various types of power sources, including thyristor, inverter, waveform-controlled, pulsed, or non-pulsed units. Since the robot control cabinet operates digitally, while most welding power sources are analog, an interface is needed between the two.
In recent years, international robot manufacturers have developed their own compatible welding equipment, which includes built-in interface boards. As a result, no additional interface box is required in the system shown in Figure 1a. It's important to note that arc welding consumes a large portion of the robot’s working cycle. Therefore, when selecting a power source, its capacity should be based on a 100% duty cycle.
The wire feeding mechanism can either be mounted on the robot’s upper arm or externally. A shorter hose between the torch and the feeder improves wire feed stability, while an external setup may cause multiple bends in the hose, negatively affecting wire quality. Hence, the installation method must ensure reliable and consistent wire feeding.
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