Types of OTC Welding Robot Wire Feeders

1. The wire feeder is divided into two types: integrated and separated according to the installation method. The wire feeder is installed on the rear of the upper arm of the robot and is integrated with the robot; The wire feeder is installed separately from the robot as a separate type.

Types of OTC Welding Robot Wire Feeders

Since the distance between the integrated wire feeder and the welding gun is shorter than that of the split type, and the hose connecting the wire feeder and the welding gun is also shorter, the wire feeding resistance of the body type is smaller than that of the split type. From the point of view of improving the stability of wire feeding, the integrated type is better than the separate type.

The integrated wire feeder, although the wire feeding hose is relatively short, but sometimes in order to facilitate the replacement of the wire spool, the wire spool or wire barrel is placed outside the safety fence away from the robot, which requires the wire feeder to have enough pulling force to pull the wire from the longer wire liner from the wire spool (barrel), and then push the welding gun through the hose For this case, the wire feeder with a larger wire feeding force is selected as the separated wire feeder with a longer wire feeding hose. Ignoring this point, the wire feeding is often unstable or even interrupted.

At present, there are more and more integrated installation methods for the wire feeder of arc welding robots, but for robots that want to automatically change the welding torch (change the diameter or type of welding wire) during the welding process, a separate wire feeder must be selected.

2. The wire feeder is divided into one pair of rollers and two pairs of rollers according to the number of rollers. The structure of the wire feeder has a pair of wire feeding rollers and two pairs of rollers; There are those that only use one motor to drive one pair or two pairs of rollers, and there are also those that use two motors to drive two pairs of rollers respectively.

From the point of view of wire feeding force, the wire feeding force of two pairs of rollers is greater than that of one pair of rollers. When flux-cored wire is used, because the flux-cored wire is relatively soft, the pressing force of the roller can not be as large as when using solid wire, in order to ensure that there is enough wire feeding thrust, the wire feeder with two pairs of rollers can have a better effect.

3. The wire feeder is divided into two types: open-loop and closed-loop according to the control mode. The wire feeding speed control method of the wire feeder can be divided into open-loop and closed-loop. At present, most of the wire feeders still use the open-loop control method, and some use servo motors equipped with photoelectric sensors (or encoders) to achieve closed-loop control of the wire feeding speed, which is not affected by the fluctuation of network voltage or wire feeding resistance, and ensures the stability of the wire feeding speed.

For pulse TIG welding of filament, a continuous wire feeder can be used, or a pulsating wire feeder that can be synchronized with the welding pulse current can be selected. The pulsation frequency of the pulsating wire feeder can be controlled by the power supply, and the length of the wire fed at each step can be adjusted arbitrarily. Pulsating wire feeders can also feed wire continuously, so there has been an increasing number of pulse TIG welding robots equipped with pulsating wire feeders for wire filling.

4. The wire feeder is divided into three types: push type, wire drawing type and push and draw type according to the direction of wire feeding power.

Wire pushing: mainly used for welding wire with a diameter of 0.8-2.0mm, it is a widely used wire feeding method. It is characterized by the simple and light structure of the welding gun, easy to operate, but the welding wire needs to go through a long wire feeding hose to enter the welding gun, the welding wire is subject to greater resistance in the hose, affecting the stability of the wire feeding, and the general hose length is 3-5m.

Wire drawing type: mainly used for thin wire (wire diameter less than or equal to 0.8mm), because the wire rigidity is small, the wire pushing process is easy to deform, and it is difficult to push the wire. Both the wire feed motor and the wire spool are mounted on the welding torch when drawing, and the drawing motor has less power due to the smaller wire feeding force, but despite this, the wire drawing welding gun is still heavier. It can be seen that although the wire drawing type ensures the stability of wire feeding, due to the heavy welding gun, the load of the robot is increased, and the operation range of the welding gun is limited.

Push-drawn wire type: The operating range of the welding torch can be increased, and the wire feeding hose can be lengthened up to 10m. In addition to the wire pusher, a wire drawing machine is also installed on the welding gun. Wire pushing is the main driving force, and wire drawing machine simply straightens the wire to reduce the wire pushing resistance. Thrust and tensile force must be well matched, usually the drawing speed should be slightly faster than pushing wire, although this method has some advantages, but due to the complex structure, troublesome adjustment, and the welding torch is heavier, so there are not many practical applications.

The wire supply device is specially designed to supply welding wire to the welding gun, and the wire pushing type single roller wire feeding method is mainly used in robot welding. That is, a transfer wire roller is arranged on one side of the wire winding frame, and then the welding wire is transferred to the welding gun through the conduit. In MIG welding of aluminum alloys, various measures have been taken to overcome the difficulty of the welding wire at the roller due to its softness, which occurs at the beginning of welding or during welding.

Types of OTC Welding Robot Wire Feeders

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