Welding robots are industrial robots engaged in welding (including cutting and spraying).
According to the International Organization for Standardization (ISO), industrial robots belong to the definition of standard welding robots.
Industrial robots are a versatile, reprogrammable automatic control manipulator with three or more programmable axes, used in the field of industrial automation.
In order to adapt to different purposes, the mechanical interface of the last axis of the robot is usually a connecting flange, which can be used to connect different tools or end effectors.
Welding robots are equipped with welding tongs or welding (cutting) guns on the end flange of industrial robots, enabling them to perform welding, cutting, or thermal spraying.
Advantages:
1) Stable and improved welding quality, able to reflect the welding quality in numerical form;
2) Improve labor productivity;
3) Improve the labor intensity of workers and enable them to work in hazardous environments;
4) Reduced the requirements for workers' operational skills;
5) Shortened the preparation cycle for product upgrades and reduced corresponding equipment investment.
Therefore, it has been widely applied in various industries.
Axis welding robot:
The workstation consists of an arc welding robot, a welding power supply, a welding gun wire feeding mechanism, a rotary dual station positioner, a fixture, and a control system.
This workstation is used for welding various workpieces based on a rotating shaft (with several cantilevers on top).
Multiple types of rotating shafts can be automatically welded within the same workstation by using different fixtures. The current welding position accuracy is very high. Due to the use of a dual station positioner, while welding, other stations can disassemble workpieces, greatly improving efficiency.
Technical indicators:
Shaft diameter: Ф 10-50mm, length 300-900mm, welding speed 3-5mm/s. The welding process adopts MAG mixed gas shielded welding, and the displacement machine rotates with a displacement accuracy of 0.05mm.
Widely used for high-quality and high-precision welding of various workpieces with rotating shafts,
Application:
suitable for industries such as :power, electrical, mechanical, and automotive.
If manual arc welding is used for shaft welding, the labor intensity of workers is extremely high, the consistency of the product is poor, and the production efficiency is low, only 2-3 pieces per hour.
After adopting an automatic welding workstation, the production can reach 15-20 pieces/hour, and the welding quality and product consistency are also greatly improved.
Axis type welding robot workstation low-voltage electrical equipment rotating shaft
| No. |
Items |
Technical parameter |
Notes |
|
| 1 |
Dimension
L*W*H |
Area occupied during storage: 1280*1040*1180mm |
|
|
| 2 |
Weight (kg) |
Total weight:About 25kg |
|
|
| 3 |
Welding type |
Gas shielded arc welding
(CO2/mixed gas) |
|
|
| 4 |
Adapted welding type |
Fillet weld, Butt weld, Circular arc weld |
|
|
| 5 |
Specification of welding machine |
According to plate thickness
350A/500A |
|
|
| 6 |
Mechanical arm |
Six-axis collaborative mechanical arm |
|
|
| Max working range:922mm |
|
| Repeated positioning accuracy:±0.02mm |
|
| 7 |
Programming mode |
Drag teaching, human-computer interface interactive programming |
|
|
| 8 |
Software interface
|
Welding process management, setting, calling and storage. |
|
|
| |
| Production operation: According to the interface operation process, human-machine collaboration and efficient programming. |
Robot parameters
| No. |
Items |
FR5 |
| 1 |
Load |
5kg |
| 2 |
Max working range |
922mm |
| 3 |
Repeated positioning accuracy |
±0.02mm |
| 4 |
Joint activity range
(soft spacing) |
1 axis : +175 -175;
2 axis : +85 -265;
3 axis : +160 -160;
4 axis : +85 -265;
5 axis : +175 -175;
6 axis : +175 -175; |
| 5 |
Joint activity range
(hard spacing) |
1 axis : +179 -179;
2 axis : +89 -269;
3 axis : +162 -162;
4 axis : +89 -269;
5 axis : +179 -179;
6 axis : +179 -179; |
| 6 |
Joint max speed |
180 degree/s |
| 7 |
Protection grade |
IP54 |
| 8 |
Noise |
<65db |
| 9 |
Installation direction |
Any direction |
| 10 |
Input/output |
Power supply (24V, 1.5A) Digital IO,Analog IO, TCP/IP communication |
| 11 |
Operating temperature |
0-45ºC |
Welding source technical parameters of the welding machine
| No. |
Welding source |
Dimension |
Titanmig X5 |
| 1 |
Rated input voltage |
V |
3~380VAC±20% |
| 2 |
Rated input capacity |
KVA |
24 |
| 3 |
Power factor |
|
0.94 |
| 4 |
Output characteristics |
|
CV |
| 5 |
Rated output current |
A |
500 |
| 6 |
Rated output voltage |
V |
39 |
| 7 |
DEVICENET interface |
|
Yes (Robot models require the optional robot adapter box) |
| 8 |
Analog communication interface |
|
Yes |
| 9 |
Rated duty cycle |
% |
60 |
| 10 |
Unload Voltage |
V |
73 |
| 11 |
Output voltage range |
V |
12-45 |
| 12 |
Output current range |
A |
30-500 |
| 13 |
Enclosure protection class |
|
IP23S |
| 14 |
Insulation grade |
|
H |
Corollary Equipment
| Device name |
Specification |
Piece |
Unit |
Condition |
Remarks |
| Welding mechanical arm |
Six-axis collaborative mechanical arm |
1 |
Set |
Normal |
Cable 3.5m (within 10m can be customized) |
| Water cooled welding machine |
Fabricated by Longway |
1 |
Set |
Normal |
5m negative cable is included (customizable) |
| Welding gun |
Fabricated by Longway |
1 |
Set |
Normal |
3.5m composite cable is included (within 5m can be customized) |
| Wire feeder |
Fabricated by Longway |
1 |
Set |
Normal |
5m composite cable is included (customizable) |
| Electric control cabinet |
Fabricated by Longway |
1 |
Set |
Normal |
Electrical apparatus elements and pipe fittings are included |
| Welding source |
Fabricated by Longway |
1 |
Set |
Normal |
500A/380V |
| Magnetic base |
Fabricated by Longway |
1 |
Set |
Normal |
|
| Tablet PC |
windows10 |
1 |
Set |
Normal |
256G |
| Software system |
Fabricated by Longway |
1 |
Set |
Normal |
Smart welding process software system |
| Update service |
Can be upgraded to a quick-plug magnetic base |
Maintenance:
A: Daily inspection and maintenance
1. Wire feeding mechanism. Including whether the wire feeding force distance is normal, whether the wire feeding duct is damaged, and whether there are abnormal alarms. 2. Is the gas flow normal. 3. Is the welding gun safety protection system functioning properly. (Prohibit turning off welding gun safety protection work) 4. Check if the water circulation system is working properly. 5. Test TCP (it is recommended to develop a testing program and run it after each shift handover)
B: Weekly inspection and maintenance
1. Scrub each axis of the robot. 2. Check the accuracy of TCP. 3. Check the residual oil level. 4. Check if the zero position of each axis of the robot is accurate. 5. Clean the filter screen behind the welding machine water tank. 6. Clean the filter screen at the compressed air inlet. 7. Clean the impurities at the welding gun nozzle to avoid blocking the water circulation. 8. Clean the wire feeding mechanism, including the wire feeding wheel, wire pressing wheel, and wire guide tube. 9. Check the hose bundle and wire guide hose for damage and breakage. (It is recommended to remove the entire hose bundle and clean it with compressed air) 10. Check whether the safety protection system of the welding gun is normal and whether the external emergency stop button is normal.
C:Monthly inspection and maintenance
1. Lubricate each axis of the robot. Add white lubricating oil to shafts 1-6. Oil number 86E006. Add butter to the red grease fittings on the RP positioner and RTS track. Oil number: 86K007 3. Add gray conductive grease to the blue oil nozzle on the RP positioner. Oil number: 86K004 4. Add lubricating oil to the needle bearing of the wire feeding wheel. (A small amount of butter is sufficient) 5. Clean the gun cleaning device and add lubricating oil to the pneumatic motor. (Normal engine oil is sufficient) 6. Clean the control cabinet and welding machine with compressed air. 7. Check the cooling water level in the welding machine water tank and replenish the coolant in a timely manner (pure water with a little industrial alcohol is sufficient). 8. Perform all weekly inspections except for completing items 1-8.
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