Mach Machines Flash Cards
Touches
refers to the programming or setting parameters related to the desired contact between the electrode or torch and the workpiece. These parameters include the timing, duration, and force of the contact. Properly setting these parameters ensures consistent and accurate welds, and it is crucial for achieving high-quality results in robotic welding.
Seam tracking
Seam tracking in robotic welding refers to the capability of a robotic welding system to accurately follow and trace the seam or joint being welded. It involves real-time monitoring and adjustment of the welding path to ensure that the welding torch or electrode stays precisely aligned with the intended welding seam.
Seam tracking is essential in situations where there may be slight variations or deviations in the position or shape of the joint. These variations can occur due to factors such as part manufacturing tolerances, fit-up inconsistencies, or thermal distortion during the welding process. By continuously tracking the seam, the robotic welding system can make dynamic adjustments to compensate for any deviations and maintain the desired weld position.
There are various techniques used for seam tracking in robotic welding, including vision-based systems, tactile sensors, laser sensors, and arc sensing technologies. These systems provide feedback to the robotic controller, enabling it to make real-time corrections and ensure accurate and consistent weld placement along the seam. Seam tracking enhances the efficiency, quality, and reliability of robotic welding operations, especially for complex or irregular joint geometries.
Why Fixturing Takes So Long
Fixturing in robotic welding can sometimes take longer due to several factors:
Design Complexity: If the parts being welded have complex shapes, contours, or multiple welding points, it can require more intricate and precise fixtures to securely hold and position the parts for welding. Designing and fabricating such fixtures may take additional time and effort.
Customization: Robotic welding often involves a wide range of different parts and product variations. Each unique part may require a custom fixture tailored to its specific shape and dimensions. Creating custom fixtures for each part can be time-consuming, especially if there are frequent design changes or a high number of unique parts.
Accuracy and Alignment: Fixtures in robotic welding need to ensure accurate alignment of the parts to achieve proper weld joint fit-up. Achieving precise alignment can be a meticulous process, involving careful measurements, adjustments, and testing to ensure that the parts are correctly positioned for welding.
Iterative Process: Fixturing may involve multiple iterations and adjustments to achieve optimal results. This iterative process includes trial-and-error adjustments, weld testing, and fixture refinements to address any issues or improve the welding process. Each iteration adds time to the overall fixturing process.
Quality and Safety Considerations: Fixtures need to provide stability, rigidity, and safety during the welding process to prevent distortion, movement, or accidents. Ensuring the quality and reliability of fixtures may involve additional steps, such as stress testing, quality checks, or safety inspections, which can prolong the fixturing timeline.
It’s important to note that while fixturing may take time initially, investing in well-designed and properly fabricated fixtures can lead to more efficient and accurate robotic welding operations in the long run, improving productivity and ensuring consistent weld quality.
Safety Features
Safety features are of utmost importance in robotic welding due to the following reasons:
Worker Safety: Robotic welding systems often involve powerful welding equipment, high temperatures, and hazardous processes. Safety features, such as barriers, safety interlocks, and light curtains, help prevent human workers from entering hazardous areas and reduce the risk of accidents, such as burns, electric shocks, or injuries from moving robot arms.
Collision Avoidance: Robotic welding systems have multiple moving components, including robot arms, welding torches, and positioners. Safety features like sensors, vision systems, and collision detection algorithms help prevent collisions between the robot and surrounding objects, machinery, or humans. These features minimize the risk of equipment damage and injury to workers.
Emergency Stop (E-stop) Functionality: In case of an emergency or unsafe condition, a properly implemented emergency stop system allows immediate shutdown of the robotic welding system. This quick response helps prevent accidents, mitigate potential hazards, and protect workers and equipment from harm.
Fire Prevention: Robotic welding involves high heat and sparks that can lead to fires or other safety hazards. Safety measures, such as fire suppression systems, spark detection systems, and proper ventilation, are crucial for preventing and mitigating fire risks in the welding environment.
Compliance with Safety Standards: Adhering to safety standards and regulations is essential for maintaining a safe working environment. Integrating safety features into robotic welding systems helps ensure compliance with applicable safety standards, such as ANSI/RIA R15.06 and ISO 10218, which are specifically designed for industrial robots.
By implementing robust safety features, employers can provide a safer working environment for their employees, reduce the risk of accidents, protect valuable equipment, and maintain compliance with safety regulations. Ultimately, prioritizing safety in robotic welding operations fosters a culture of safety and well-being for everyone involved.
Seam Finding
Seam finding, also known as seam detection or seam tracking, is a process used in robotic welding to identify and locate the welding seam or joint on a workpiece. The purpose of seam finding is to enable the welding robot to accurately follow and weld along the desired seam.
Seam finding can be performed using various sensing technologies, depending on the specific application and requirements. Some common methods include:
Vision-based Seam Finding: This technique utilizes cameras or vision systems to capture images of the workpiece and analyze them to identify the seam’s location. Image processing algorithms are employed to detect and track features or patterns associated with the seam, such as changes in color, contrast, or geometry.
Laser-based Seam Finding: Laser sensors emit a laser beam onto the workpiece surface and measure the reflections to determine the seam’s position. The sensor detects variations in the reflected laser beam caused by the seam, enabling the robot to track its location.
Tactile or Touch-based Seam Finding: In this method, the robot’s end-effector or a dedicated touch sensor comes into physical contact with the workpiece. By moving along the surface, the sensor detects changes in force or resistance that indicate the presence of the seam.
Seam finding algorithms analyze the sensor data and provide feedback to the robotic controller, allowing it to adjust the robot’s trajectory in real-time. This ensures that the welding torch or electrode stays precisely aligned with the seam during the welding process, compensating for any variations or deviations in the seam’s position or shape.
Seam finding plays a crucial role in achieving accurate and consistent welds, especially in situations where there may be slight variations in the position or shape of the joint. It enhances the efficiency, quality, and reliability of robotic welding operations, enabling precise weld placement and minimizing the risk of welding defects.
Arc World 6000
Arc World 6000 - Automation means speed and efficiency, and our ArcWorld® 6000 maximizes both wiith multiple robots, space-saving indexing positioners, and coordinated motion between the robot and positioned part. Built for the most demanding production enviroments, the ArcWorld 6000 will have your medium and larger parts processed with incredible productivity and quality.
- Up to three AR1440 or AR2010 robots can be combined for HyperProductivity.
- Optional area scanner provides in-cell and under-positioner safety.
- Optional roll-up door reduces work cell footprint.
- Coordinated motion technology allows multiple robots to be synchronized with the positioner and other external axes.
- Ferris wheel positioners provide infinite part positioning, enabling the weld joint to be kept in a gravity-neutral welding plane, improving weld quality.
- Sealed positioner drives and SIGMA 7 servo motors minimize required maintenance.
- Patented MotoMount™ fixture mounting system facilitates fixture changes and extends life by reducing stresses in bearings.
- Reduced cycle time due to fast overhead sweep, comfortable load height and optimal programming/ processing position.
ArcWorld 2000
When it comes to large parts and heavy-deposition welding, only a truly heavy-duty solution will suffice. Our large ArcWorld® robotic workcells deliver maximum power for performance on a whole new scale, without sacrificing safety features and ease of integration that characterize our smaller workcells.
- Two-station configuration enables simultaneous welding on one station, while loading/unloading on the opposite station.
- One or two AR2010 or AR3120 Motoman® high-speed arc welding robots for improved throughput and quality.
- Tooling spans can be 3, 4 or 5 meters with a variety of positioners to support varying part sizes.
- Servo-driven headstock and tailstock support payloads up to 6,300 kg.
- One- or two-station configurations can be designed with a blank station, allowing the installation of end user-supplied fixturing.
- MotoMount™ fixture mounting system simplifies tooling and reduces stress on positioner bearings.
- Positioner jogging available at operator station to aid loading and unloading of parts.
ArcWorld 1000
Inspired by one of our first and most popular ArcWorld® designs, the ArcWorld 1000 series utilizes a turntable to index parts for processing while the operator loads and unloads parts. Designed to be highly portable, the common base and integrated design allow this workcell to be deployed quickly anywhere in your plant.
- Welding workcell designed for general fabricators with high production requirements.
- Space-saving design features a common platform for the robot, positioner and safety fencing for quick, easy setup.
- Sliding interlocked doors on each side of workcell provide easy programming access.
- Available with one or two AR1440 high-speed arc welding robots.
- Positioner available with 355-, 655-, and 1,055-kg payload capacity.
- 1,524 mm (60”) turning diameter; divided by a protective arc screen that allows the operator to safely load and unload parts from one location outside the robot work envelope, while the robot welds inside the workcell.
- Optional 1,828 mm (72”) turning diameter table is available.
- Designed to accommodate single- or multiple-fixture part run. Fixtures are easily located on the table using dowel pins.
ArcWorld 200 & 500
Having multiple parts to weld doesn’t always require the use of multiple complex workcells. The ArcWorld® 200 and 500 series offer two workstations with choice of table or part positioner–you can even mix and match. Process different parts in each workstation, or double up production on the same part. The compact size and common base allow you to deploy this system quickly on your shop floor.
- Customizable, dual-station workcells designed for small- to medium-sized parts or medium quantity production runs.
- Each workstation features an electrically driven metal barrier door with two-second cycle time.
- A single high-speed Motoman® AR1440 arc welding robot services both workstations.
-AW200 features 600 mm x 1300 mm workstations designed for stationary tooling or tack table. - AW200 risers are provided to allow end users to place their own tooling in workstation.
- AW500 workstation includes an MHT185 positioner that is rated for 550-kg payload capacity and features coordinated motion with the robot.
ArcWorld 50 Series
Parts don’t have to have lengthy arc on times to justify automation. Our ArcWorld® 50 Series condenses the quality of our popular pre-engineered weld workcells to allow you to efficiently automate your smaller parts on this incredibly dynamic and robust workcell. The fast automated door offers nearly instantaneous access to processed parts in a single- or dual-station configuration. Positioner options allow you to turn parts to reach weldments on all sides with perfect coordinated motion.
- Designed specifically for production of small- to medium-sized parts.
- Available in single (AW50) or dual station (AW52) models with tables or servo positioners.
- The robot controller and welding equipment are mounted on a docking base to simplify shipment and installation.
- AR1440 arc welding robot provides 1440 mm reach with high repeatability.
- Powered roll-up door(s) improve operator ergonomics.
- Tooling risers are provided for the fixed-station workcells. Dowel pins can be used for changeover between multiple parts/fixtures.
- Single 1650 mm tabletop (AW50) or two 775 mm tabletops (AW52) with 685 mm depth are available as options.
- Poistioner options of up to 185 kg payload to turn parts while welding.
Cobot - HC10
Automating your welding process doesn’t have to involve large welding systems for your small and medium parts. With features like lead-to-teach and power force limited sensors, our HC10 collaborative robot allows us to shrink the size of a workcell down to a welding table. The ArcWorld® HC is a complete, yet flexible, solution to automating your welding process. Whether it’s your first robot, or simply augmenting another automated process, the HC10 is built on the same industrial platform as the rest of our AR series welding robots—so you can have extreme reliability and full compatibility as your production grows.
- Highly flexible workcell helps to supplement manual welding
- Requires only 3.7 square meters of valuable floorspace.
- A single human-collaborative Motoman® HC10 arc welding robot welds parts with efficiency and consistent high quality.
- Choice of Miller®, Lincoln, or Fronius power supplies.
- Welding processes are accessed by Yaskawa’s Universal Weldcom Interface directly from the robot programming pendant.
- Perforated weld fixturing table with a 1000 kg payload.
- Wide usable area allows for multiple small parts to be processed or singular large part.
- Processes parts up to 500 x 2000 x 800 mm in size. (HxWxD)
Positioners and limitations
Available in two diameters - 1,524 mm and 1,829 mm.
Payload per side, 355, 655, 1,055
