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The automatic arc welding robot workstation has seen significant technological advancements, offering a range of benefits. These include improved stability and enhanced welding quality, increased labor productivity, reduced physical strain on workers, and the ability to operate in hazardous environments. Additionally, it lowers the technical requirements for operators, shortens the preparation time for product modifications, and reduces the need for extensive equipment investment.
Welding robots typically consist of two main components: the robot itself and the welding equipment. The robot includes a robotic arm and a control cabinet, which encompasses both hardware and software systems. As for the welding equipment, arc welding and spot welding systems are composed of a power source (with its control system), a wire feeder (for arc welding), and a welding torch or clamp. For more advanced, intelligent robots, additional sensing systems such as laser or camera sensors may be integrated along with their respective controls. Figures 1a and 1b illustrate the basic components of an arc welding robot and a spot welding robot, respectively.
**Features of Arc Welding Robots**
(1) **Basic Functionality**
The arc welding process is far more complex than 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 specialized functions beyond general capabilities. While a five-axis robot can technically perform arc welding, it is often insufficient for complex welds. Unless the weld is simple, a six-axis robot is recommended for better flexibility and precision.
In addition to the standard features, arc welding robots should be capable of following a "Zigzag" or small-diameter circular welding path closely. They should also support different swing patterns, allowing for programmed swing welding. During each cycle, the robot should pause at the designated point and stop moving forward to meet the welding requirements. Additional features like contact positioning, automatic weld start detection, arc tracking, and automatic re-ignition are essential for efficient operation.
(2) **Welding Equipment for Arc Robots**
Arc welding robots commonly use gas-shielded welding methods such as MAG, MIG, or TIG. They can be equipped with various types of power sources, including thyristor-based, inverter-based, waveform-controlled, or pulsed/non-pulsed units. Since the robot’s control cabinet operates digitally, while most welding power sources are analog, an interface is usually required between them. In recent years, foreign manufacturers have developed their own compatible welding equipment, often incorporating built-in interface boards, eliminating the need for an extra interface box. This is evident 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, it should be chosen based on a 100% duty cycle rating to ensure continuous performance.
The wire feeding mechanism can either be mounted on the robot’s upper arm or externally. A shorter hose between the torch and feeder improves wire stability, whereas a longer hose, especially when the robot moves the torch to certain positions, can cause multiple bends and negatively affect the wire feed quality. Thus, the installation method must prioritize consistent and reliable wire feeding.
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