Integrating a robotic welding system within a manufacturing facility comes with a decision backed by reliable data. There must be a case made to switch to automation. A robotic welding system transforms any production line with its precise welds, repeatability, and speed. Factory workers rely on welding robots to perform a the same task and execute a duplicate weld each and every time at speeds that human labor cannot match.
Automating any welding application with a robot will provide practical value in many ways. When debating the addition of a robotic cell, it’s important to look beyond the robot. If a factory is seeking to incorporate arc welding into their process and serve as the primary source for the cell, then it’s imperative that the gun and consumables are thought of properly. Consider the following tips when completing a robotic welding system integration with a gas metal, arc welding gun or a GMAW.
Always request preventive maintenance for a GMAW
Equipment breaks down. It’s a simple fact of life. The environment industrial equipment operates within comes with risks that significantly increase issues occurring. When a company invests in robotic welding cells, productivity gains are sought and if downtime occurs due to preventive maintenance guidelines not being met revenue dips. The preventive maintenance directive for GMAWs can vary widely based on the manufacturer.
ICR’s field service team are adept at identifying issues with GMAWs on-site. Technicians will check for secure, clean connections between the neck, diffuser, and the contact tip. If the links appear safe, then they next look at the seals to make sure there is no leakage. These checks should occur on a regular basis outside of a PM visit to ensure a satisfactory weld each time.
Features abound
As with all equipment, features are an important component that determines the purchasability of the unit. Featured options on a GMAW could include an air blast or even a wire brake. The goal of manufacturers in regards to developing feature options focuses on improving the machine, but keeping its speed, quality, and repeatability in check.
Debris removal on a robotic weld gun can be an issue, which is why the air blast feature was developed. Blowing high-pressure air through the front of the weld gun achieves a level of debris removal that makes this function a reliable option. Look for a wire braking mechanism as it’s another optional feature of interest to most. This option prevents any wires from feeding through the gun once the welding has finished.
When it comes to robotic GMAW guns, one size does not fit all
GMAWs come in a variety of sizes. Particular attention to the type of application the system will be tasked with while in operation is important to know. The material that will be welded, thickness, amperage and require arc-on time are all important factors to consider. If amperage applications are of chief concern, then an air-cooled option should be considered. These type of guns deliver optimal results when a small amperage use on thin materials are needed.
When high-amperage welding is needed, water-cooled guns work best. Since high-amperage welding requires longer operating times, they come equipped with an external cooler. However, due to the extra addition, a higher up-front cost is associated with this style of gun. With the extra cost comes the assurance of fewer chances of overheating.
When ready to add a robotic welding cell to your production line, submit a quote request or phone our robotic specialists at (866)9-ROBOTS.
We’ve shown the video before, but it fits perfectly with our blog post. Check out the video below, which features a GMAW in action.
