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Report Robot Welding
Report Robot Welding
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
by
LUCKNOW
CERTIFICATE
HOD.
Asst. Professor
BBDNITM, Lucknow
BBDNITM, Lucknow
Date:
ACKNOWLEDGEMENT
We deeply wish to express our heartfelt gratefulness and gratitude to the following people
who guided and supported us in every step of my work.
It is our pleasure to offer my sincerest gratitude to my guide Mr. Prashant Tripathi,
Professor, Dept. of Mechanical Engineering, BBDNITM, Lucknow, who has guided and
supported us throughout the project with his patience and knowledge. His guidance, serenity,
commitment, strictness and support helped us to complete this work.
We would like to express our heartiest gratitude to Prof. S.P. Asthana, Head of Mechanical
Engineering Department, BBDNITM, Lucknow, for his unconditional support and permission to
use the departmental labs.
We are thankful to the faculty members who have been the part of our seminar and
presentations, for their valuable observations and guidance. We take this opportunity to extend
our regards to the lab instructors who helped us with their skills and hard work during our
project.
We are also grateful to respected Prof. Dr. Seethalakshmi K., Director, Babu Banarasi Das
National Institute of Technology and Management, Lucknow, for providing us a great academic
environment where we can transform our self as asset of the nation.
Finally, we would like to thank my parents for their blessing and care.
INDEX
SR.NO.
TOPICS
PAGE
NO.
1
1.
ABSTRACT
2.
ROBOT WELDING
3.
WELDING PROCESS
4.
11
5.
16
6.
WELDING SAFETY
17
7.
ADVANTAGES
18
8.
CONCLUSION
19
9.
REFERENCES
20
ABSTRACT
1. ROBOT WELDING
When should robots be used for welding?
2. WELDING PROCESSES
Welding is the most economical and efficient way to join metals
permanently. Welding is used to join all of the commercial metals and to join
metals of different types and strengths.
All arc-welding processes use an arc welding gun or torch to transmit welding
current from a welding cable to the electrode. They also provide for shielding
the weld area from the atmosphere.
The nozzle of the torch is close to the arc and will gradually pick up
spatter. A torch cleaner (normally automatic) is often used in robot arc
welding systems to remove the spatter. All of the continuous electrode wire
arc processes require an electrode feeder to feed the consumable electrode
wire into the arc.
Welding fixtures and workpiece manipulators hold and position parts to
ensure precise welding by the robot. The productivity of the robot-welding
cell is speeded up by having an automatically rotating or switching fixture, so
that the operator can be fixing one set of parts while the robot is welding
another.
To be able to guarantee that the electrode tip and the tool frame are
accurately known with respect to each other, the calibration process of the
TCP (Tool Center Point) is important. An automatic TCP calibration device
facilitates this time consuming task.
TYPICAL COMPONENTS
WELDING CELL:
1.
2.
3.
4.
5.
6.
7.
OF
AN
INTEGRATED
ROBOTIC
ARC-
arc to weld in areas that are difficult to reach. Even so, a robot cannot
provide the same manipulative motion as a human being, although it can
come extremely close. In addition, jointed arm robots are the most compact
and provide the largest work envelope relative to their size. Usually arcwelding robots have five or six free programmable arms or axes.
Off-the-shelf programmable robot arms are today available from different
suppliers such as ABB, FANUC, PANASONIC, KUKA, MOTOMAN.
welding process such as gas metal arc or flux cored arc welding, and
shielding gas may or may not be employed.
There are two basic types of wire feeders. The first type is used for the
consumable electrode wire process and is known as an electrode wire feeder.
The electrode is part of the welding circuit, and the melted metal from the
electrode crosses the arc to become the weld deposit. There are two different
types of electrode wire feeders. The constant-power power source requires a
voltage-sensing wire feed system in which the feed rate may be changing
continously. The constant-voltage system requires a constant feed rate
during the welding operation.
The second type of wire feeder is known as a cold wire feeder and is
especially used for gas tungsten arc welding. The electrode is not part of the
circuit, and the filler wire fed into the arc area melts from the heat of the arc
and becomes the weld metal.
positioners are used to improve the versatility and to extend the range of
robotic arc welding systems. The usable portion of a robot work envelope can
be limited becuse the
welding torch mounting method does not allow the torch to reach the joint
properly. Special positioners eliminate some of these limitations by making
the workpiece more accessible to the robot welding torch.
The positioners used with robots also have to be more accurate than
required for manual or semiautomatic welding. In addition the robot
positioner controls must be compatible and controllable by the robot
controller in order to have simultaneous coordinated motion of several axes
while welding.
However, loading and unloading stationary jigs of the robot cell can be time
consuming and impractical. It is often more efficient to have two or more
fixtures on a revolving workpiece positioner, despite a higher initial cost.
With a revolving table for instance, the operator can load and unload while
the robot is welding. Obviously, this speeds up the process and keeps the
robot welding as much of the time as possible.
2.1.6 TORCH CLEANER
Periodic cleaning of arc welding guns is required for proper and reliable
operation of robotic arc welding equipment. The high duty cycle of an
automatic operation may require automated gun cleaning. Systems are
available that spray an antispatter agent into the nozzle of the gun.
Additionally, tools that ream the nozzle to remove accumulated spatter and
cut the wire are available. The cleaning system is automatically activated at
required intervals by the welding control system.
2.1.7
TCP-
CALIBRATION UNIT
End-of-arm
sensor and tool centre
point calibration
is a critical aspect of
successful system implementation. End-of-arm sensing, in the context of
robotic welding, is used to detect the actual position of the seam on the
workpiece with respect to the robot tool frame.
Analysis of the profile data yields the relative position of the seam with
respect to the sensor reference frame. If the sensor reference frame pose is
known with respect to the end-frame of the robot, and the tool frame pose is
known with respect to the end-frame, then the sensor data may be used to
accurately position the tool centre point (TCP) with respect to the workpiece.
While end-of-arm sensor based control would appear to solve both robot
accuracy and workpiece position error problems, this is only so if the sensor
frame, end frame, and tool frame are accurately known with respect to each
other.
Should the sensor be accidentally knocked out of position, the robot
system becomes a highly consistent scrap production facility. Indeed, this
very concern has been one of the reasons why some companies that would
benefit from a sensor based correction system have been reluctant to
implement such a system. What is required is not only a technique that
enables the frames to be automatically calibrated, but that also enables the
system to quickly determine if recalibration is necessary. This second
capability is perhaps the more important in practice, since it can be
reasonably assumed that any calibration error will be caused by an
unanticipated event that could occur during any welding cycle.
Duri
ng
the
resistance
welding process the welding electrodes are exposed to severe heat and
pressure. In time, these factors begin to deform (mushroom) the electrodes.
To restore the shape of the electrodes, an automatic tip-dresser is used.
One problem when welding with robots is that the cables and hoses used
for current and air etc. tend to limit the capacity of movement of the robot
wrist. A solution to this problem is the swivel, which permits passage of
compressed air, cooling water, electric current and signals within a single
rotating unit. The swivel unit also enables off-line programming as all cables
and hoses can be routed along defined paths of the robot arm.
Spot
robots
have
more
motion
welding
should
six
ore
axes
of
and
be
capable of
approaching points in the work envelope from any angle. This permits the
robot to be flexible in positioning a welding gun to weld an assembly. Some
movements that are awkward for an operator, such as positioning the
welding gun upside down, are easily performed by a robot.
Less work space needed -No mass of cables and hoses hanging from
the robot arm, resulting in floor space economy.
Improved accessability - Since no limitation on the robot wrist caused
by any cables or hoses.
This
is how bodies are
created in car construction that are significantly stiffer in case of a crash, for
example, and thus provide greater safety for passengers.
Furthermore, laser welding always requires access from one side only, so
newdesigns are now possible that could not nave been implemented by
means of traditional resistance spot welding.
3. WELDING SAFETY
Welding is an established manufacturing process with known potential
hazards. Potential safety hazards associated with arc welding include arc
radiation, air contamination, electrical shock, fire and explosion, compressed
gases, and other hazards. Robots were originally designed to perform the job
functions of a human. They were designed to relieve humans of the drudgery
of unpleasant, fatiguing, or repetitive tasks and also to remove humans from
a potentially hazardous environment. In this regard, robots can replace
humans in the performance of dangerous jobs and are considered beneficial
for preventing industrial accidents. On the other hand, robots have caused
fatal accidents.
CONCLUSION
At present relatively few figures are available on the economics of robot
Welding machines, but it has been found that numbers of components
produced by A robot are 2.5 to 3.5 times greater than that produced
manually over the same Span of the time. It can be said that for an output of
more than 100 parts/month which takes two or three shift per day there is an
increase in number of parts output without difference in quality, which is not
necessarily so with manual shift work.
REFERENCES
1. www.ukros.com/robot_welding
2. www.weldingengineer.com
3. www.autotech-robotics.com
4. www.robot-automation.com
5. www.robot-welding.com