Phoenix designs affordable turnkey welding robot solutions and complete robotic welding systems for MIG, TIG, and robotic ARC welding. They can also design robotic welding cells for your specific needs.
Are you looking for a particular robot for the welding process at the moment?
At Phoenix, we have in-depth knowledge and experience across all robot manufacturers including, KUKA welding robot, ABB welding robot, Fanuc welding robot, and Kawasaki welding robot. If you already have an established robot partner, we work with you to help to choose a manufacturer or we recommend a robot that meet your expectation for robotic ARC welding, Seam welding, MIG welding, Spot welding, Laser, and TIG welding applications. We also work together with our partners to provide the quickest and best options on the market.
See below the top 5 types of robotic welding systems, we are happy to help you with any of them.
Top 5 Types of Robotic Welding Cells
Here are the top five types of robotic welding systems that are commonly used in the manufacturing industries: Arc welding cell, spot welding cell, laser welding cell, resistance welding cell, and robotic welding workcell with multiple processes.
Robotic MIG welding robots are versatile, and can handle MIG, TIG, and SAW welding techniques. MIG welding is a popular technique that uses a consumable electrode wire and a shielding gas to create an electric arc for welding.
Spot welding is a resistance welding process used to join two or more metal sheets together. The main spot welding materials include stainless steel, nickel alloys, and titanium. Even though the melting point is lower, welding is possible.
Laser welding cells use robots equipped with laser welding heads that employ high-energy laser beams to melt and join metal parts. Robotic laser welding is based on laser beams. Although conventional welding may be cheaper, robotic laser welding is more efficient and user-friendly.
Resistance welding cells use robots for performing different resistance welding processes, including seam welding, projection welding, or flash welding. It is a highly effective welding process that employs the heat generated by the electrical resistance between the workpieces to create welds.
Robotic welding workcells with multiple processes are used in manufacturing operations. They incorporate robots that can perform different welding techniques, such as arc welding, spot welding, and laser welding. These robotic welding systems offer flexibility and efficiency by integrating multiple welding processes into a unified system.
Components of an Arc Welding Robots
Arc welding robots consist of a robotic manipulator with articulated arms and joints. In addition to the main components, safety measures are also included in the welding cell to ensure safety, such as physical barriers, safety sensors, emergency stop buttons, and interlocks. These safety features prevent access to the cell while welding operations are being performed and ensure that operators are safe.
Moreover, there is a programming and control system managed through a dedicated control panel or human-machine interface (HMI). This allows operators to program, monitor, and control the robot’s actions, welding parameters, and settings. Therefore, the interface plays a critical role in maintaining optimal performance.
It is essential to maintain a focus on safety and ensure that every aspect functions efficiently for safe and precise arc welding operations. If these concepts are unfamiliar to you, our company can guide you through the entire process.
Welding Power Source
A welding power source is essential in providing the required electrical energy for welding. Moreover, it delivers voltage, current, and welding parameters for the welding application. MIG, TIG, and SAW are common power source types, all designed for efficient and precise welding. Therefore, choosing the right power source is key to achieving high-quality and durable welding results.
Torch Cleaning Station
Clean your welding equipment regularly to prevent contamination and ensure high-quality welds. Additionally, use a torch cleaning station for effective and careful cleaning to remove any debris from the torch and maintain its top condition. Moreover, prioritize this maintenance routine for optimum equipment performance.
Welding Wire Feeder
MIG and flux-cored arc welding use a wire feeder to supply welding wire during the welding process. The feeder continuously feeds the welding wire, resulting in a flawless welding process that is cost-effective, efficient, and generates less waste. As a result, this creates a stronger bond between metal parts and wire feeders have become essential in modern arc welding.
Main Elements of the Robotic Welding Systems
When choosing a robotic welding system, it’s important to understand the key components, like the robot, gun, controller, and power source. Other factors may be needed, such as wire feeders, positioners, or safety features. By evaluating these aspects and your specific project needs, you can pick the right system.
The main elements of robotic welding systems consist of various components that work together to automate the welding process. These systems generally include a robot manipulator, welding power supply, welding torch, controller, and safety equipment. Hence, each component plays a vital role in ensuring the accuracy, reliability, and efficiency of the robotic welding process.
The robot manipulator is the main component of the system, responsible for precisely controlling the welding torch and ensuring that the desired welding pattern is achieved. The welding power supply provides the necessary energy to generate an arc and melt the metal. Meanwhile, the welding torch delivers the filler material and controls the weld bead’s width through a nozzle. The controller is where the operator programs, monitors, and coordinates the robot’s movements and welding process. Ultimately, safety equipment is essential to ensure the safety of operators and prevent accidents during the welding process.
When choosing a robotic welding system, it is important to consider a few key factors. Firstly, you should evaluate the various components such as the robot, gun, controller, and power source. In addition, specific applications may require additional components such as feeders, positioners, fixtures, and safety features. Therefore, it is vital to carefully select the correct robotic welding system for your project. By taking the time to evaluate the various factors involved, you can ensure that you find the best possible solution to meet your needs.
Key elements that make up the majority of a robotic welding cell
Choose the right robotic welding cell by evaluating the key elements listed below. Also, consider wire feeders, positioners, fixtures, and safety features based on your project’s needs.
Consider payload, reach, torch weight, and turntable axis when investing in robotic welding.
For accurate welding, use welding jigs to guide the cutting, support the workpiece and position everything correctly. Fixture jigs are necessary when working with multiple parts. Welding clamps hold material together while welding. Use these tools to ensure welding projects are accurate and successful.
A commonly used part presentation turntable in robotic applications has two positions, one for the operator and the other for the robot. Controlled by a simple motor mechanism and an output signal, the turntable is used for reliable and precise handling of manufacturing parts.
Our team will install advanced welding components, including a torch, weld controller, and signal processor, supervised by a central control unit. We’ll also install a tip cleaner to keep the system in prime condition. Our setup ensures accurate, high-quality, and efficient welding for utmost professionalism and proficiency.
To ensure a secure working environment, it is important to guard the cell while the robot operates. Two-channel safety systems are integrated into the equipment to provide protection against welding flash and reinforce safety standards in the workspace.
However, when it comes to producing welding tool paths, there are essentially two methods used in welding automation. The first method involves hand-teaching by jogging the robot from the teach pendant and recording the positions. The alternative is to use offline CAD-CAM software to prepare the tool paths. This is the most common method used where there is a diversity of paths.
Two position Welding Turntable
A welding turntable is a useful tool for welding tasks as it allows for consistent and precise welds by rotating the workpiece to optimal angles. A two-position turntable provides added flexibility, saving time and effort by eliminating manual repositioning and increasing productivity.
It is common for installations to feature some form of two-position turntable (see examples of welding system turntables). This allows for completed parts to be removed and new parts to be loaded while the robot is welding the previously loaded parts.
It may also be necessary to reorient parts during the welding process to enable better access to the torch or to maintain a horizontal weld path. In the case of this type of workpiece presentation, there will be two stations: one for the operator to load and unload and another for the robot to carry out the welding operations. However, the rotational axis, in this case, will be part of the robot’s own movement.
Two or three additional axes will also be provided for each station, allowing the robot to rotate the part both horizontally and vertically.
Robotic Welding Systems
Electrical Control Panel Robot
Companies should consider adding a control panel to their robotic welding cell to ensure versatility and safety of the robot cell.
The robot cell safety panel with cell control push buttons should be installed to fully control the cell, and the panel should be electrically connected to the robot controller. This panel must also include safety relays for the two safety circuits for both the robot and the positioner.
One circuit is for the Estops, which stops the robot in all modes, while another circuit is for cell access. This circuit will stop the robot and positioner simultaneously when the access door to the cell is opened and the robot is in Auto mode. If you need full robot integration, do not worry because we can help you find a suitable robot and the appropriate control panel.
Advantages of Welding Robots
More and more, industrial robots are being used for performing welding operations, where traditionally, this process was manual. There are clear advantages to using six-axis robotic welding.
The working condition of welding is not ideal for workers, but robots remain unaffected by welding flash, heat, or fumes. Additionally, the robot arm can run for 24 hours a day and 7 days a week if required.
Once programmed, the robot’s path is repeatable and consistent. As a result, the robot can produce good welds, and each run on that cell will have the same quality as previous jobs.
Phoenix offers a variety of system integration support services in our portfolio, catering to all stages of any robotic integration project. Click below to learn more about the most common robotic cells.
Turnkey Industrial Robot Solutions
Phoenix integrates and installs complete robotic milling solutions from initial design and consultation to manufacture. We also offer robot training, robot programming, robot simulation, commissioning, and technical support. Whether you decide to configure your complete milling robot cell around a new or reconditioned robot, we can assist you. For more information For more see our article Robotic Integrator in Manufacturing.