(1) Welding deviation issue: It may be due to incorrect welding position or problems with the welding gun during searching. At this point, it is necessary to consider whether the TCP (center point position of the welding gun) is accurate and adjust it accordingly. If this situation occurs frequently, it is necessary to check the zero position of each axis of the robot and recalibrate it for correction.
(2) Undercut problem: It may be due to improper selection of welding parameters, incorrect welding gun angle or position, and can be adjusted appropriately.
(3) Blowhole problem: It may be due to poor gas protection, too thick primer on the workpiece, or insufficient drying of the protective gas. Corresponding adjustments can be made to handle it.
(4) Excessive splashing problem: It may be due to improper selection of welding parameters, gas composition reasons, or excessive extension length of welding wire. The machine power can be adjusted appropriately to change the welding parameters, the gas proportioner can be adjusted to adjust the mixed gas ratio, and the relative position of the welding gun and the workpiece can be adjusted.
(5) The problem of forming an arc crater after cooling at the end of the weld seam: When programmable, adding a buried arc crater function in the work step can fill it up.
Common faults in robot systems during the welding process
(1) Gun collision: It may be due to deviation in workpiece assembly or inaccurate TCP of the welding gun. The assembly situation can be checked or the TCP of the welding gun can be corrected.
(2) In case of Arc fault, the arc cannot be struck: it may be because the welding wire does not contact 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 alarm: If there is a malfunction in the cooling water or protective gas supply, check the cooling water or protective gas pipeline.
Programming skills for welding robots
(1) Choose a reasonable welding sequence to reduce welding deformation and the length of the welding gun travel path to formulate the welding sequence.
(2) The space transition of the welding gun requires a short, smooth, and safe movement trajectory.
(3) Optimize welding parameters, in order to obtain the best welding parameters, make working specimens for welding tests and process evaluation.
(4) Use a reasonable positioner position, welding gun posture, and the position of the welding gun relative to the joint. After the workpiece is fixed on the positioner, if the welding seam is not in the ideal position and angle, it is required to continuously adjust the positioner during programming, so that the welded seam reaches the horizontal position one by one according to the welding sequence. At the same time, it is necessary to constantly adjust the position of each axis of the robot, reasonably determine the position and angle of the welding gun relative to the joint and the extension length of the welding wire. After determining the position of the workpiece, the position of the welding gun relative to the joint must be observed with the programmer's eyes, which is difficult. This requires programmers to be good at summarizing and accumulating experience.
(5) Insert the cleaning program in a timely manner. After writing a certain length of welding program, the cleaning program should be inserted in a timely manner to prevent welding spatter from blocking the welding nozzle and conducting nozzle, ensure the cleanliness of the welding gun, improve the lifespan of the nozzle, ensure reliable arc striking, and reduce welding spatter.
(6) Generally, programming cannot be done in one step. A good program can be formed only by constantly checking and modifying the program, adjusting welding parameters and welding gun posture during Robot welding.