ROBOTIC WELDING

ROBOTIC WELDING

Mahatma Gandhi Missions College of Engineering and Technology Noida, U.P., India

Presented by:PraveenGuided by:MR. A.K. SinhaIntroduction to weldingRobotic welding Needs of robotic weldingRobotic arc weldingRobotic spot weldingRobot anatomyRobotic welding torchFeatures of robotic welding

CONTENTROBOTIC WELDINGBenefits of robotic weldingApplications Recent advances Challenges in robotic weldingConclusion References ROBOTIC WELDINGWELDINGWelding is a metal joining process which produces coalescence of metals by heating them with or without using filler material. It can be pressurized or non-pressurized.

ROBOTIC WELDING(Welding processes)ROBOTIC WELDINGROBOTIC WELDINGIt is a welding process that is performed & controlled by robotic equipments.It was first introduced in United States industries during the 1960s.It mainly uses GMAW & resistance spot welding process.

ROBOTIC WELDINGNEEDS OF ROBOTIC WELDINGRobotic welding was required:To avoid hazardous work environmentsFor repetitive work cycleFor consistency and accuracyTo do difficult handling tasks for humansFor multi shift operations

ROBOTIC WELDING7Principle of arc welding consists of establishing an electric arc between a metal electrode and the work piece.

It generally involves GMAW process, which is also known as MIG welding or MAG welding process.

A power is required to arc weld which is supplied by the welding machine, known as power source.

Welding torch is used to transmit current from a welding cable to electrode.

ROBOTIC ARC WELDINGROBOTIC WELDINGA torch cleaner is often used to remove the spatter.

It requires a electrode feeder to feed the consumable electrode wire into the arc.

Work piece fixture holds & position parts to ensure precise welding by the robot.

TCP guarantees that the electrode tip & the tool frame are known to each other.ROBOTIC WELDINGCOMPONENTS OF ARC WELDING CELLArc welding robot

Power source

Welding torch

Work fixtures

Torch cleaner

TCP calibration unit

ROBOTIC WELDINGSpot welding is a pressurized welding process.

Resistance of the base metal to electrical current flow causes localized heating in the joint.

A spot welding gun applies a appropriate pressure & current to the sheets to be weld.

During welding process, electrode is subjected to severe heat & pressure due to which it begins to deform (mushroom shape).

To restore the shape of the electrode, tip dresser is used.

ROBOTIC SPOT WELDINGROBOTIC WELDINGComponents Of Spot Welding CellSpot welding robot

Welding gun

Electrode tip dresser

Spot welding swivel

ROBOTIC WELDINGRobot consists of a manipulator which is a series of mechanical links and joints capable of producing all sorts of designed movements. The body, arm and wrist assembly of a robot is called as a manipulator. Each link of a manipulator is operated by either hydraulic or pneumatic power cylinder or electrical motors. The forearm of a robot can move in a nearly spherical way, thus covering a large work volume and providing greater application flexibility.

ROBOT ANATOMYROBOTIC WELDING

Joint 3

Link 3Joint 2BaseJoint 1Link 1End of armLink 4Link 2(Robot anatomy)ROBOTIC WELDINGROBOTIC WELDING TORCH Three variants are available as option: straight, 22 angled, or 45 angled. All three variants impress through a robust construction, with the torch neck manufactured in stainless steel, capable of withstanding the most arduous of conditions.

ROBOTIC WELDINGFEATURES OF ROBOTIC WELDINGMotion control systemWork volume and degrees of freedomPrecision of motionProgramming Interface with other systemROBOTIC WELDINGBENEFITS OF ROBOTIC WELDINGImproved product qualityHigh precision and productivityDecreases scrap and reworkReduced labor costOperators safety

ROBOTIC WELDINGRobotic welding is widely used in automotive industry.It is used in manufacturing plants.It is used in dockyards to weld heavy parts of ships.

APPLICATIONSROBOTIC WELDINGRecent advances in robotic welding technology is pipe welding during ship fabrication.It is able to weld the joints in any position.

RECENT ADVANCESROBOTIC WELDING

CHALLENGES IN ROBOTIC WELDINGIt is difficult to do welding insides of tanks, pressure vessels, and ship hulls. Humans can position in to these areas more readily than robots.

One of the most difficult technical problems is the variation in the dimensions of the parts in a batch production job.

Another technical difficulty is the variations in the edges and surfaces to be welded together. This causes variations in the gap between the parts and other problems in the way the pieces mate together prior to the welding process.

It is very costly to set up.

ROBOTIC WELDINGThis technology of robotics relieve people from boring, repetitive, hazardous and unpleasant work as human labor.

Robots can accomplish routine, undesirable work better than humans at a lower cost. Automation of work through robotics will lead to substantial increase in productivity, and that productivity increases year by year & would permit humans to engage in activities that are cultural and recreational.

Not only will robotics improve our standard of living, it will also improve our standard of life. CONCLUSIONROBOTIC WELDINGhttp://www.wikipedia.org/wiki/robotic-weldinghttp://www.robot-welding.com/welding_process.htmhttp://www.robots.com/applications/arc-weldingWelding Robots Technology System Issues and Applications - J Norberto PiresThe Welding Institute, UK, http://www.twi.co.uk

REFERENCESROBOTIC WELDINGTHANK YOU