1. Robot system failure
(1) A collision occurred. It may be due to deviations in the assembly of the workpiece or inaccurate TCP of the welding gun, the assembly can be checked or the TCP of the welding torch can be corrected.
(2) If there is an arc fault, the arc cannot be initiated. It may be because the wire is not in contact with 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 and alarm. If there is a fault in the cooling water or shielding gas supply, check the cooling water or shielding gas line.
Second, how to ensure the quality of the workpiece
As a teach-in reproducible robot, the assembly quality and accuracy of the workpiece must be of good consistency.
The application of welding robots should strictly control the preparation quality of parts and improve the assembly accuracy of weldments. Part surface quality, groove size, and assembly accuracy will affect weld tracking results. The quality of part preparation and the accuracy of weldment assembly can be improved from the following aspects.
(1) Compile a special welding process for welding robots, and carry out strict process regulations on part size, weld groove and assembly size. Generally, the dimensional tolerance of parts and grooves is controlled at ±0.8mm, and the assembly dimensional error is controlled within ±1.5mm, and the probability of welding defects such as porosity and undercut in the weld can be greatly reduced.
(2) The assembly tooling with high precision is used to improve the assembly accuracy of the weldment.
(3) The weld should be cleaned, free of oil, rust, welding slag, slag cutting and other sundries, and weldable primer is allowed. Otherwise, the success rate of arc striking will be affected. Positioning welding is changed from electrode welding to gas shielded welding, and the spot welding part is polished at the same time to avoid the residual slag shell or porosity due to positioning welding, so as to avoid the instability of the arc and even the generation of spatter.
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