What You Must Know About Robotic Welding

Again, tap the knowledge of a robotic welding integrator for advice and assistance to optimize their process flow.

CONSUMABLES
The MIG guns and consumables on the robot can impact productivity and profitability. Together, the robotic MIG gun and consumables on a robot are responsible for directing the current to the arc to complete the weld, making them integral components in the whole system. To gain the best quality and to avoid expensive downtime for maintenance, repairs or replacement, select a robotic MIG gun that is suitable for the amperage, duty cycle and cooling capacity needed in the application.

Using a robotic MIG gun that offers inadequate cooling or amperage can cause performance issues and lead to premature failure – both factors that increase costs and downtime. Likewise, using a robotic MIG gun that offers higher amperages than necessary raises the total cost of ownership, as typically the cost of a robotic MIG gun increases directly in proportion to its amperage.

Carefully select the consumables – the contact tips, nozzles, retaining heads (diffusers) and liners – and manage them properly in order to gain optimal productivity and lower costs. Heavy- or extended-duty contact tips and nozzles, for example, are a good choice to withstand the heat of higher amperage applications and can help
minimize downtime for changeover. Conversely, lower amperage applications or ones with shorter arc times may be better suited to standard-duty consumables, which also tend to cost less.

As with robotic MIG guns, carefully matching the type of consumables to the application can prevent having to address premature failures and/or accrue costly downtime (not to mention lapses in production). This match can also prevent overpaying for consumables that may be too much for the application. Consider the mode of welding when selecting consumables, as technology such as pulsed welding tends to be especially harsh on consumables and often requires heavy-duty options to withstand the heat of the arc for longer periods of time.

PERIPHERALS
Peripherals – any additional equipment integrated into the robotic welding system to maximize its performance – can help improve the return on investment in a robotic welding operation. Peripherals include items such as a nozzle cleaning station (sometimes called a reamer or spatter cleaner), anti-spatter sprayers, wire cutters and neck alignment tools.

Unfortunately, some shops downplay the value of peripherals and view them as an unnecessary cost. They don’t realize how they can play an important role in reducing downtime and rework, improving quality and increasing productivity.

Consider a nozzle cleaning station, for example. As its name implies, this peripheral cleans the nozzle of dirt, debris and spatter, typically during routine pauses in the robotic welding operation. This cleaning action helps prevent shielding gas coverage loss that could lead to weld defects, expensive rework and lost productivity. The equipment also helps the front-end consumables last longer, and longer consumable life means less downtime for changeover and less expense for replacements.

The addition of an anti-spatter sprayer further improves consumable life and performance by adding an anti-spatter compound that serves as a protective barrier against spatter buildup and other contaminants.

In the long run, the up-front investment in peripherals such as these can lead to measurable savings and provide a better return on investment by aiding the robot in doing what it does best: make and complete consistent, high-quality welds for longer periods of time than a semi-automatic welding operation.

SKILLED LABOR
Having skilled operators with proper training to oversee the robotic weld cell is critical. Robotic welding operations require ongoing supervision and maintenance, and that job needs to be completed by a skilled operator who has undergone the proper training.

When considering an investment in robotic welding, take care to evaluate the available pool of talent. As a rule, skilled welding operators and/or employees with prior robotic welding experience are the best candidates to supervise the weld cell. After the proper training, which a robotic integrator or OEM typically offers, these employees can provide the necessary operating and troubleshooting skills to ensure the maximum uptime in the robotic welding cell.

As part of the routine training, it is absolutely necessary for the operators who will be overseeing the robot to be able to schedule and perform routine preventive maintenance on the system. Implementing preventive maintenance helps minimize unnecessary downtime and keeps the robotic welding system running more smoothly. If problems can be solved before they arise and the robotic welding equipment made to last longer, it can protect the financial investment and ensure the productivity and profitability sought by this equipment in the first place.

Consider vetting robotic welding integrators to determine the availability and costs associated with the training of personnel. Training typically lasts one to three weeks, depending on the certification level desired, and continuing tutorials are often available.

In the end, careful planning, good equipment selection and proper training are all “must-knows” for managing a profitable and productive robotic welding operation. So whether a shop is new to robotic welding or trying to improve an existing operation, knowing some key factors can go a long way in helping to gain a competitive edge and making the most out of the investment.