What problems are likely to occur when using welding robots

After the beginning of industrial society, the manufacturing industry has a huge demand for welding. Manual welding is labor-intensive and has a poor working environment, which has led to fewer and fewer people engaging in welding. At the same time, the quality of manual welding cannot be unified and is difficult to control. With the beginning of Industry 4.0, welding has begun to replace manual labor to complete most repetitive welding work. Welding robots can continue welding operations in harsh environments, which saves companies a lot of labor costs. However, during the operation of welding robots, welding problems will also occur over time or due to manual misoperation. So, what problems are likely to occur when using welding robots?

1. Ending crater problem

If an arc crater is formed at the end of the weld after cooling, you can add the arc crater function in the work step to fill it.

2. Welding bias problem

During manual welding, the weld trajectory is changed in real time through human eye observation. During robot welding, the trajectory of the welding robot is generally completed through machine teaching. The program after teaching is fixed. If the armor position of the workpiece is not offset, it may be caused by the welding robot. The TCP coordinate definition is inaccurate. Generally, the TCP coordinate of the welding robot is defined at the end of the welding gun. If there is a deviation during the calibration of the coordinate system, it will cause the trajectory of the welding robot to change. This will lead to the occurrence of offset welding. The solution to this problem is to recalibrate the working coordinate system of the welding robot.

3. Biting phenomenon occurs

The phenomenon of undercutting may be caused by improper settings of the welding machine parameters of the welding robot. Such as welding, welding voltage and other parameters. It can be solved by reasonably adjusting the characteristics of the parts. Another situation is that the position, angle and distance between the welding gun and the weld show that the position of the welding gun is deviated, the angle is too large or too small, and the distance between the welding gun and the weld does not match the diameter of the welding wire used, which will cause undercutting. In the process of welding robot programming, control the position, angle and distance to avoid undercutting during welding.

4. Porosity problem

The pores may be caused by poor gas protection, too thick primer on the workpiece or insufficient dryness of the protective gas, which can be adjusted accordingly.

5. Excessive splashing

If there is too much spatter during robot welding, it may be due to improper selection of welding machine parameters or excessive elongation of welding wire. At this time, you can adjust the welding machine parameters and gas ratio appropriately.

The above are the problems that are prone to occur in the work of welding robots and their solutions. Reasonable avoidance and quick resolution of these problems can effectively improve the robot's welding efficiency and welding quality, while reducing the company's production costs and improving the company's benefits.