1. Welding deviation problem: it may be that the welding position is incorrect or there is a problem when looking for the welding gun. In this case, it is necessary to consider whether the TCP (welding torch center point position) is accurate and adjust it. If this situation occurs frequently, it is necessary to check the zero position of each axis of the robot and re-calibrate it to correct.
2. Undercut problem: it may be due to improper selection of welding parameters, wrong angle of welding torch or position of welding gun, which can be adjusted appropriately.
3. Porosity problems: it may be that the gas protection is poor, the primer of the workpiece is too thick or the protective gas is not dry enough, and it can be dealt with the corresponding adjustments.
4. Excessive spatter: It may be due to improper selection of welding parameters, gas composition or too long extension of the welding wire, the size of the machine power can be appropriately adjusted to change the welding parameters, the gas ratio instrument can be adjusted to adjust the proportion of mixed gas, and the relative position of the welding gun and the workpiece can be adjusted.
5. An arc pit is formed after cooling at the end of the weld: the buried arc pit function can be added to the working step when programmable, and it can be filled.
6. Common faults of the system during the welding process
1) Collision gun: It may be due to the deviation of the workpiece assembly or the inaccuracy of the TCP of the welding gun, you can check the assembly situation or correct the TCP of the welding gun.
2) If there is an arc fault, the arc cannot be initiated: it may be because the welding wire does not contact the workpiece or the process parameters are too small, the wire can be fed manually, the distance between the welding gun and the weld can be adjusted, or the process parameters can be adjusted appropriately.
3) Protective gas monitoring alarm: if there is a fault in the supply of cooling water or protective gas, check the cooling water or protective gas pipeline.
7. Programming skills of welding robots
1) Select a reasonable welding sequence to reduce the welding deformation and the length of the walking path of the welding torch to formulate the welding sequence.
2) The spatial transition of the welding torch requires a short, smooth and safe movement trajectory.
3) Optimize the welding parameters, in order to obtain the best welding parameters, make working specimens for welding test and process evaluation.
4) Adopt a reasonable positioner position, welding torch attitude, and welding torch relative to the joint position. After the workpiece is fixed on the positioner, if the weld is not the ideal position and angle, it is required to continuously adjust the positioner during programming, so that the welded weld reaches the horizontal position one by one according to the welding order. At the same time, the position of each axis of the robot should be continuously adjusted to reasonably determine the position, angle and length of the welding wire relative to the welding gun. Once the position of the workpiece has been determined, the position of the welding torch relative to the joint must be observed by the programmer's eyes, which is difficult. This requires programmers to be good at summarizing and accumulating experience.
5) Insert the gun cleaning program in time, and after compiling a certain length of welding program, the gun cleaning program should be inserted in time, which can prevent welding spatter from blocking the welding nozzle and contact tip, ensure the cleanliness of the welding gun, improve the life of the nozzle, ensure reliable arc starting, and reduce welding spatter.
6) The preparation of the program can not be done in one step, and it is necessary to continuously inspect and modify the program in the process of robot welding, adjust the welding parameters and the attitude of the welding gun, etc., so as to form a good program.
8. Welding robot operating cost and management
The price of imported robot accessories is high, and efforts should be made to reduce the cost of operation from all aspects. Lubricants can be found in China to find low-cost alternatives with the same performance and effectiveness. The welding process strengthens maintenance and improves the service life of consumables such as nozzles and contact tips. In addition, preventive maintenance of the robot system can effectively improve the service life of the components.
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