What Is Robotic Welding? Structure Of Industrial Welding Robot

Entering the industrial revolution 4.0, many businesses around the world are gradually focusing on investing in the development and production of service (support) robots. Industrial welding robots are one of the most widely used robots.

What is robotic welding?

Industrial welding robots are a type of mechanized tool that completely automates the process by both performing welds and processing welded parts.

Specialized industrial welding robots

• Arc Welding Robot
• Spot Welding Robot
• Resistance Welding Robot
• Robotic TIG Welding
• Robotic MIG Welding
• Laser Welding Robot
• Plasma Welding Robot

Each type of industrial welding robot used in automated lines is designed and manufactured with the highest precision. Their expertise lies in handling complex machining positions that require high accuracy, such as in the production of cars, motorcycles, etc. 

Structure of Robotic welding

Welding power source

• Generates electricity to generate heat for the welding process.
• The welding power source must be sufficient with the appropriate voltage for the welding process.
• Shielded gas supply lines and cables.

Welding robot arm

• Multi-axis or linear motion type welding robot arms. 
• The reach and payload of a robot affect the size of the items it can weld. (That is, the distance it can move and the weight it can support over that distance). 
• Wide swivel joints add flexibility and range of motion. Industrial welding robots easily access different welding angles so that they can weld in any position.

Welding gun/ Torch

• The welding gun transmits the electrode to the weld site, creating a protective environment around the weld.
• Includes Electrode Wire Holder (bulk) and wire feeder for MIG welding or TIG arc welding.
• Electrodes for resistance spot welding
• Laser for laser welding
• Peripherals such as wire cutters for trimming excess wire, nozzle/tip cleaning station, soldering tip replacement station, coatings and sheaths to protect cables, tools and parts from splatter. 
• Welding guns are straight or curved. Usually attached to the robot body.

Welding fixture, welding positioner

The welding workpiece needs to be held steady so that the welding robot can operate as required.

• Large parts may require a turntable or servo-controlled gantry.
• The fixture is designed to be flexible, easy to operate, and still ensure strength during welding. 
• An important thing is how to design a frame to hold the welding objects at the appropriate location. This part must be quick and easy to operate, hold the solder objects firmly until they stick together, and must allow the welding gun free access to the weld.

Sensor

Options include collision sensors to avoid contact with soldering irons or other dangerous equipment.

• Seam finding sensor to ensure weld quality and position.
• Tool center point (TCP) sensing for proper weld placement.
• Sensors and cameras to verify clamp and part position.

Safety tools

Pressure sensitive safety mats and personal protective equipment.

• Interlock switches prevent the machine from operating or starting a new cycle unless closed.
• Safety lock to prevent opening or removal of safety guard.
• Sensors, infrared beams, safety shutters and blackout curtains.

Electronic Controls and Interfaces (HMI)

HMIs can be simple or complex, depending on the application. Includes a button or an array of switches or a multi-screen computer application that controls all aspects of the work (e.g., part positioning, sensor monitoring, discharge parts, and transport to the next station).

It is important to consider the level of access for different people working with the device. For example, what features should be regulated by the operator and which should be restricted to programmers or maintenance technicians?

In some applications, the handheld device allows the operator to easily program the robot’s movements and store them as a program to run. Other applications, especially those that run at high speeds or with short cycle times, require more programming experience.

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