Welding is one of the main application scenarios of industrial robots, accounting for more than 20% of the total downstream applications of industrial robots. In 2021, the global welding robot market size will be 62.6 billion yuan, and the market size of China's welding robot will be 24.8 billion yuan, and it is expected that in 23-27 years, the global welding robot market will grow rapidly at a compound growth rate of 9%, and the overall global welding robot market size is expected to reach 107.8 billion yuan by 2027. Such a huge market demand makes welding a battleground in the field of robotics.
According to the classification of welding process, welding robots can be divided into spot welding robots, arc welding robots, laser welding robots and other types, among which spot welding and arc welding are the current mainstream models. The arc welding equipment is small and lightweight, and is generally used with lightweight six-joint robots of 6-20kg level; The spot welding equipment is large and heavy, and is generally used with heavy-duty six-joint robots of the 160-210kg level; Laser welding equipment has high requirements for accuracy, and generally needs to be matched with welding positioners to achieve flexible welding of complex curved welds or large weldments.
Laser welding robots are divided into 3-axis, 4-axis, and other customized robots according to the type, and customized robots can meet the welding needs of different fields. Research data show that in 2018, the customization demand for laser welding robots accounted for 6.03% of the market share, and the compound growth rate from 2019 to 2024 was 15.04%.
Recently, Elite collaborative robots equipped with related equipment have been successfully introduced into the field of laser welding. So why did the company use Elite cobots for this project? Let's dive in!
This company is engaged in the research and development of emerging energy technology and electronic components, capacitors and accessories and other products manufacturing enterprises, the company in the production of manufacturing mainly used materials are aluminum products, and laser welding technology is very popular in the welding of aluminum parts, so the company began to introduce hand-held welding machines for laser fusion welding of parts many years ago.
In recent years, affected by the epidemic, the company has also begun to face problems such as difficulty in recruiting workers, rising labor costs, etc., coupled with the expansion of business scope, as well as the increasing requirements of end customers for products, the consistency, production efficiency and yield rate of handheld welding products are increasingly unable to meet customer requirements, so customers urgently need to introduce appropriate automation equipment to fundamentally solve the problem.
01 Laser welding robot
After alignment and communication with the customer, the final choice was to use Elite EC66 collaborative robot with Hanrui laser, its power is 2000W, the wavelength range is 1070±10nm, and the output fiber core diameter is 30μm.
02 Laser welding robot
In this application, the advantages of the compact structure of the cobot are fully realized, and it can be put into use directly integrated into the workbench, and it can also allow the staff to view the welding situation in real time, and truly realize the man-machine shared work area. In addition, Elite combines the welding process with collaborative robots, so that the advantages of welding robots are brought into full play, and the production pain points are effectively solved for customers:
Trigger command can be flexibly controlled
Efficiency, automation, flexibility and digitalization are the directions for the development of integrated design of welding robot systems. After full communication and alignment with the customer, Elite paid attention to the laser welding process, which mainly includes the power setting of the laser generator during welding and the accurate on/off control of the laser generator by the robot. It takes a certain amount of time for the laser generator to reach the set power or to shut down completely.
This requires the robot to be able to turn on/off the laser generator in advance at a specific position of the welding trajectory according to the set early time/distance to achieve the best welding effect. According to customer needs, Elite Robot has developed the corresponding Trigger command, which allows users to easily set up I/O control based on the set position of early time (or distance), that is, the movement does not stop and at the same time accurately control the I/O.
2. Truly achieve fast programming
Elite robot end I/O supports custom function configuration, including but not limited to recording the current point, inserting motion statements, inserting custom command groups, etc. In this project, after the user sets the laser welding power parameters in advance, he only needs to quickly insert the motion command and insert the functions of "start welding"/"end welding" through the two buttons on the dragging device at the end of the robot, which truly allows the user to achieve the rapid programming of "dragging" - "recording" - "production".
3. There is no need to change the layout of the original production line
Elite EC66 collaborative robot, load 6kg, weight only 17.5kg, the robot is integrated into the application workstation, the whole set of application workbench is nearly 1.5m³, can be quickly deployed into the factory production line, no need to move the original equipment of the factory to change the original layout of the factory.
4. Safety anti-collision protection of man-machine safety
Elite collaborative robot welding process package provides a highly sensitive collision detection function, when the robot or terminal mechanism accidentally touches people or obstacles, the system will immediately stop welding, fully protect the safety of people and equipment. After the shutdown, the staff can reset through the host computer and quickly resume production.
5. The best inclination is 10-15 degrees
In the laser fusion welding process, the laser irradiation direction also needs to be deflected at a certain angle with the welding surface, and the tilt of 10-15° during welding has the best effect.
Laser welding & collaborative robots
Laser welding is an efficient and precise welding method that uses a high energy density laser as a heat source. This means that even the smallest solder joints and sensitive electronic components can be connected. Laser welding offers a number of advantages over normal welding, conventional welding, or case hardening:
1 Compared to traditional thermal spray technology, laser welding provides a dense coating with almost no porosity, a finer surface, more consistent layer thickness, and more accurate coating placement.
2 The welding process requires very little heat input, almost no dilution, fine microstructure, small heat-affected zone (HAZ) and low deformation.
3In some applications, laser welding restores parts to their original dimensions without additional manual intervention.
4. Improves the material's natural resistance to corrosion, abrasion and oxidation.
With the development of lightweight and miniaturization, laser welding robots will also show diversified characteristics, I believe that collaborative robots with their own advantages of "no guardrails, small and flexible, rapid deployment" and other advantages, will help the need to customize laser welding enterprises to find a new breakthrough, the process needs to be improved, collaborative robots are promising!
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