Introduction of Welding
Welding is an effective and economical way to join metals constantly. Welding is used in combination with all commercial metals and with various strengths and advantages.
One is manufactured with or without the application of pressure to welding welds with or without pressure application with or without pressure. There are various welding processes that use different heat sources. For example, the arc is used as a heat source. Another commonly used welding process is the spot welding (welding).
Introduction of CNC Technology
Technology continues to be adopted in different sectors with the underlying objective of enhancing efficiency and effectiveness. The manufacturing industry is also seeing an increased investment in technological dynamics to incorporate its tenets in manufacturing processes to improve its output. CNC machining is best defined as a modern day set of special computers that aim at bolstering precision and speed when controlling numerical machines. In addition to this, Computer Numerical Control (CNC) operates by interpreting sets of numerical instructions from a distinct controller so that they can function in a more effective manner.
Examples of manufacturing processes that have seen successful incorporation of CNC machining are thermal controllers and coordinates on a select axis. In the modern-day manufacturing industry, precision and speed are dynamics that are critical considering that they help to prevent delays. Perfection has become a common and expected outcome within the sector thus issues such as half-inch errors and delays are addressed with the presence of technology. Outlining the relevance of CNC machining as a modern technological tool that enhances manufacturing processes is characterized by showcasing its advantages, its benefits to the manufacturing industry, highlighting its uniqueness, and the way it improves productivity.
CNC (Robot Welding)
Modern technology is everything that we want to weld; Handmade but the modern process has done wonders by using technology like the 21st-century robotics.
A robot is a mechanical device or an artificial body with control by CNC. It usually indicates that the system has a purpose or agency in its appearance or activity. But it refers to the bot to distinguish it.
There are many things in a robot while discussing what a robot can be.
This means that nature is not ‘nature’
- Be aware of its environment;
- Ability to make choices based on the environment. Usually, automatic control or pre-set plans are used.
- Operates with one or more axes of a translation or translation article
- Dexterous coordination
- It seems to have a purpose or agency
Basic of CNC (Robot) Welding
Rectilinear CNC (Robot) move along any line in three axes (X, Y and Z). In addition to the linear movement of the robot along the circle, the robot has a wrist to allow rotation. This creates a working robot that depicts the box.
Articulating robots utilize arms and rotating joints. These robots are like human arms. This creates an invalid robot-work zone, known as the work arc.
There are several factors to consider when building a robot welding machine. Engineer welding requires different engineering than manual welding. The following are some considerations for the CNC (robot) welding industry.
The selected CNC welding designed include start / stop, gas pre flushing, electrode feed and nozzle flushing. Robots have been used about 15 years to weld complete automotive body assembly and sub assembly components. In general equipment for automatic arc welding is designed in a different way from that used for manual arc welding. Automatic arc welding normally involves high duty cycles, and the welding equipment must able to operate under those conditions. In supplements, the equipment components must have the necessary features and controls to interface with the CNC control system.
Types of CNC (Robot) Welding
An autonomous mobile robot system with a visual sensor for automatic welding was developed. Algorithm for recognition of welding line and automatic seam-tracking was constructed. The robot has a movable arm of which position is controlled on cylindrical coordinates and two driving wheels which are equipped at both sides of the vehicle body. The CCD camera is equipped on the movable arm and detects welding line from upper side of base materials. The constructed system can recognize welding line with a visual sensor robustly and track welding line with enough precision and speed as basic performance of welding robot. Consequently, it was confirmed that the system has enough availability and effectiveness to automatic welding. The following welding operations that can be performed by robots are as follows:
- Arc welding
- MIG welding
- TIG welding
- Spot welding
CNC (Robot) Arc Welding
Representing 20% of all robotic applications, arc welding is one of the most common functions in industry today. During this process, electricity jumps from an electrode guided through the seam, to the metal product. This electric arc generates intense heat, enough to melt the metal at the joint. Sometimes the electron is simply a conductor that guides the arc. Other times the rod or wire is composed to become part of the weld.
The Benefits of CNC (Robot) Arc Welding are:
- Uniformity of quality welds
- Lowered production costs
- Fewer get rid of parts
- Increase your return on investment (ROI)
- Fewer injuries from weld splatter or fumes
- Speed – faster part cycle time
CNC (Robot) MIG Welding
Gas Metal Arc Welding (GMAW) is often referred to as MIG welding. MIG welding is a commonly used high deposition rate welding process. Wire is continuously fed from a spool. MIG welding is therefore referred to as a semiautomatic welding process.
The Benefits of MIG Welding are:
All position capability. Higher deposition rates that SMAW.
CNC (Robot) TIG Welding Process: Gas Tungsten
Gas Tungsten Arc Welding (GTAW) is frequently referred to as TIG welding. TIG welding is a commonly used high quality welding process. TIG welding has become a popular choice of welding processes when high quality, precision welding is required. In TIG welding an arc is formed between a non-consumable tungsten electrode and the metal being welded. Gas is fed through the torch to shield the electrode and molten weld pool. If filler wire is used, it is added to the weld pool separately.
The Benefits of TIG Welding are:
Superior quality welds. Welds can be made with or without filler metal. Precise control of welding variables (heat). Free of spatter. Low distortion
CNC (Robot) Spot Welding Robots
In spot welding, two copper alloy electrodes are used to sandwich metal sheets together. The electrical current conducted by the electrodes melts the heat-affected zone between. Spot welding is widespread in the automotive industry.
Unfortunately, spot welding can create hazards in the workplace. Workers must labor under the weight of the heavy welding guns, endure the fumes and sparks created by this process, while matching every spot-welding requirement.
With robots, spot welding is reliable, and workers are removed from the danger zone.
The Benefits of Spot Welding are:
- Consistent weld quality, accuracy
- High repeatability
- Less wasted material
- Fast throughput and cycle time
- Safer work environment
- Good return on investment (ROI)
The Benefits of CNC (Robots) Welding
A welding process that contains repetitive tasks on similar pieces might be suitable for automation. The number of items of any type to be welded determines whether automating a process or not. If parts normally need adjustment to fit together correctly, or if joints to be welded are too wide or in different positions from piece to piece, automating the procedure will be difficult or impossible. Robots work well for repetitive tasks or similar pieces that involve welds in more than one axis or where access to the pieces is difficult.
Automating the torch motions decreases the error potential which means decreased scrap and rework. With robot welding you can also get an increased output. Not only does a robot work faster, the fact that a fully equipped and optimized robot cell can run for 24 hours a day, 365 days a year without breaks makes it more efficient than a manual weld cell.
Another benefit of automated welding is the reduced labor costs. Robotic welding also reduces risk by moving the human welder/operator away from hazardous fumes and molten metal close to the welding arc Welding is the most complex of all manufacturing technologies. In order to transform welding from a manual operation to an automated production process, it is necessary to understand the scientific principles involved.
Car manufacturing by CNC (Robot) Welding
In this scientific age the manufactures are utilizing welding robots as much as 500 nos. manufacturing robots for a single assembly by producing consistent quality. The robots are becoming intelligent and faster and now come equipped with the ability to see as well.
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 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.
The introduction of robots requires appropriate safety features in order to protect both those working directly with the robot and others in the workshop who may not be aware of its potential dangers. This can be provided in a few ways. One of the best solutions for robot safety is to purchase a complete welding cell from a robotic integrator. A complete cell includes barriers, all necessary safety devices, and a method of loading and unloading the workstation.
Each robot installation must be carefully planned from safety viewpoint to eliminate hazards. When the robot is in operation it is necessary that people remain outside the work envelope. All doors and maintenance openings must be protected by safety switches, and the weld areas must be safe guarded so that the power is immediately removed from the robot when a door is opened. Emergency stop buttons should be placed on all operator panels, robot cabinets and robot programming panels. Barriers must be designed to surround the robot and eliminate the possibility of people climbing over or under to get inside the barrier. Signal lights must be arranged on the robot or in the robot area to indicate that the robot is powered.
CNC (Robot) Welding technology has raised the production much more than the manual welding. There is no hazard in working even in hazardous conditions. Besides the products will be more durable and smooth finish having top quality control so that it will attract the consumers. Therefore, the producers prefer for robot welding for mass production at less price. There is improved productivity in the manufacturing process through its operational dynamics that pay attention to speed and precision. As a result, the manufacturing process has managed to use this aspect of technology to raise the optimum levels of performance as well as increase profits that are generated. All the same, outlined the relevance of CNC (Robot) machining as a modern technological tool is showcased by its ability to enhance manufacturing processes. Such characteristics transcend to its advantages, its benefits to the manufacturing industry, its uniqueness, and improved productivity.