NEXT STEPS IN ROBOTIC WELDING

These best-in-class robots and control systems serve the welding and metal fabrication markets that are currently the primary growth areas for robotics.

EXTENDED REACH WELDING ROBOT
The MA3100 “Master Arc” welding robot from Motoman (Dayton, OH) features an extended-reach arm that reduces the need for tracks. It is the longest robot arm designed for arc welding. Available in floor-, wall- or ceiling-mounted configurations and ideal for multiple robot layouts, the MA3100 reduces welding cycle time due to cutting-edge Sigma-5 motor control technology and new ARM (Advanced Robot Motion) control.

The MA3100 has a 3 kg (6.6 lb) payload, 3,121 mm (122.9 in) horizontal reach, 5,615 mm (221.1 in) vertical reach and ±0.15 mm (±0.006 in) repeatability. Its integrated through-the arm cabling eliminates cable interference, simplifies programming and reduces cable wear. Welding utilities (gas hose and feeder signals) can be routed through the robot base. The MA3100 is perfectly suited for use in workcells with larger workpieces, as well as for applications that require access to parts in tight spots or those with possible interference from fixtures.

The MA3100 robot uses the dynamic, next-generation DX100 controller that features patented multiple robot control technology to easily handle multiple tasks and control up to eight robots (72 axes), I/O devices, and communication protocols. Featuring a robust PC architecture with unmatched memory capacity, the DX100 uses a Windows® CE programming pendant with color touch screen. Menu-driven arc welding software is provided. Digital welding interfaces are supported for Miller Auto-Axcess^™ and other brands of power sources.

The energy-saving DX100 controller features faster processing speeds for smoother interpolation, advanced robot arm motion, built-in collision avoidance, quicker I/O response and accelerated Ethernet communication. It is compliant to ANSI/RIA 15.06-1999 and other relevant ISO and CSA safety standards. www.motoman.com

THROUGH-THE-ARC SEAM TRACKING
ABB Robotics (Auburn Hills, MI) presents WeldGuide® III, an adaptive sensing system that performs weld seam joint tracking during the welding process, identifying variations in the weld joints to proactively correct the robotic torch path. Utilizing voltage and current sensors, the system takes real-time measurements through the welding arc to make any adjustments necessary to keep the robotic welding torch in the joint path no matter the programming. A combination of hardware and software specifically designed for the newer IRC5 controller, WeldGuide III is half the price and easier to implement than the Advance Weld Controller (AWC) system that ABB has used since 1994. WeldGuide III requires less initial programming than traditional robotic welding control systems and is ideal for applications on heavy weldments.

This system is especially effective for heavy deposition welds, where a 1 mm to 2 mm weave pattern must be used to fill the gap between the parts; applications where the welding seam location moves slightly or more from part to part; parts where multiple passes are required to complete the weld.

In such heavy, high heat welds, WeldGuide III provides more precise path accuracy and better weld integrity than would be achieved with standard welding systems. With the tracking system automatically adapting to the part, WeldGuide III provides more consistent welds, even on parts where there is considerable part variation, providing far better throughput and less re-weld situations. The system is so easy to use and cost effective that it is even appropriate for the smallest job shops.

Primary application areas for WeldGuide III on robotic welding systems include off-highway and agricultural equipment, transportation, defense, and other manufacturers that fabricate large, heavy metal parts requiring longer, wider welds. www.abb.com/robotics

ROBOTIC WELDING EDUCATION CELL
The Lincoln Electric Company (Cleveland, OH) and FANUC Robotics America, Inc. (Rochester Hills, MI) partnered to offer the industry and educational partners a welding solution focused on enhancing the ability to train students on robotic programming and welding. The system and program are designed to provide access to the best curriculum, materials and system. The goal is to help instructors and students develop the skills necessary to thrive in an advanced manufacturing environment.

The Education Cell is focused on educational institutions, company training departments and other schools and facilities that teach robotic programming as it relates to gas metal arc welding processes. Created for both classroom and lab use to provide the best hands-on and instructor-led programs. Delivered with the curriculum a staff can follow to teach robotic programming and use, as well as standard GMAW by the industry experts.

Developed to enhance school and community capabilities and competencies with the addition of robotic welding and programming courses. Designed to fit through a standard doorway; the Education Cell can be moved from classroom to classroom and positioned for best viewing during training. Ready to go, the Education Cell provides everything a welder needs right at their fingertips –integrated gas bottle, consumable and fume extraction mounting, integrated safety measures, and standard software options from FANUC.

The cell features a Lincoln Electric Power Wave® 355M and AutoDrive™ 4R90 welding package with an FANUC ARC Mate® 50iC/5L with ArcTool software – a complete robotic hardware and software solution. www.lincolnelectric.com, www.fanucrobotics.com

INTEGRATED WELDING CELL
The ArcWorld® IV-6200SL “slim line” solution from Motoman (Dayton, OH) features dual MA1400 “Master Arc” welding robots with multiple robot control, a high-speed trunnion positioner, integrated welding package, operator interface and a total safety environment. Independent drive on each of the three positioner axes enables the operator to index the load station or allows both stations to turn while the positioner sweeps, saving cycle time.

The MRM2-250M3XSL and MRM2-750M3XSL positioners feature the fastest indexing time in their class. They are available with 250 kg (551.3 lb) or 750 kg (1,653.8 lb) payloads. The 250 kg payload version indexes in 1.75 sec; the 750 kg payload version indexes in 2.5 sec. The slim line positioner, a redesign of an existing positioner, reduces floorspace. The width of the positioner/workcell is only 1 m wider than the fixture span. Because the positioner can be serviced from the front of the workcell, additional space can be saved by placing cells next to each other without aisles. These positioners are available in standard lengths of 2 m and 3 m between mounting surfaces, but can easily be extended. They provide a turning diameter of 1.3 m (51.2 in) to accommodate large parts and tooling.

The MRM2-250M3XSL and MRM2-750M3XSL positioners utilize independent servo motor drives on each of the three axes for high-speed positioning. This reduces cycle times by allowing fixtures to rotate into working position while the main sweep axis indexes between stations. Application flexibility is also a benefit because the load station can be programmed to a more ergonomic orientation. The operator can also jog the load station if manual tack welding is required.

The positioners utilize the MotoMountTM fixture mounting system. This patented design eliminates stresses from poor fixture alignment from being transferred into the bearings or servo drives. MotoMount also provides a horizontal mounting surface with locating pins for easier fixture changeover.

The workcell is available with Motoman’s leading multiple robot control technology. Two, three or even four welding robots can be incorporated into the cell and controlled from a single teach pendant. The ArcWorld workcell is available with an optional nozzle cleaner. It can also be combined with automatic tip checking devices such as ToolSight® or ToolSight6D. ToolSight is designed to automatically detect variation in wire position (TCP) before parts are produced.

A PC-based Human Machine Interface (HMI) is available to show cell and production related data. The HMI provides local control for memory backup and displays diagnostic data in an easy-to-read format on a color touch screen. Cell I/O and uptime data is presented graphically. Screens are also provided to allow operators to edit weld positions. www.motoman.com

LASER SENSOR INCREASES QUALITY, SPEED OF WELDING
A laser sensor from British manufacturer Meta Vision Systems Ltd. (Eynsham, UK) for all types of mechanized and robotic welding is the first such sensor to incorporate high performance image processing in the sensor head itself, rather than needing a separate computer, and has many applications throughout manufacturing industry.

Installing the Smart Laser Sensor (SLS) at least halves the cost of automating arc welding equipment and robot welders, compared with using conventional laser sensors. The cost can be a small fraction of the previous outlay if the welding equipment has an Ethernet or CANbus interface, allowing direct connection of the SLS. Other functions of the SLS, in addition to seam tracking during welding, include inspection of the bevel on pipe ends before welding, and of the weld bead after it is laid. All three processes have been performed with tracking position detection and measuring accuracy to within ± 0.1 mm.