Resolving welding defects in welding robots typically involves the following aspects:
1. Parameter optimization:
Welding process parameters: Adjust welding current, voltage, speed, gas flow rate, electrode angle and other parameters to match the welding material, thickness, joint form, etc. Correct parameter settings can avoid issues such as welding deviation, undercutting, porosity, and splashing.
Swing parameters: For situations that require swing welding, optimize swing amplitude, frequency, starting and ending angles, etc., to improve weld formation and prevent defects.
2. Welding gun and workpiece positioning:
TCP calibration: Ensure the accuracy of the welding gun center point (TCP) to avoid welding deviation caused by inaccurate positioning.
Workpiece fixture: Ensure that the workpiece fixture is stable and accurately positioned to avoid welding defects caused by workpiece deformation during the welding process.
3. Weld seam tracking technology:
Visual Sensor: Real-time monitoring of weld position and shape using visual or laser sensors, automatic adjustment of welding gun trajectory, ensuring weld tracking accuracy, and reducing defects.
Arc sensing: dynamically adjust welding parameters and welding gun posture through feedback information such as arc voltage and current, adapt to surface changes of the workpiece, and prevent welding deviation and undercutting.
4. Gas protection:
Gas purity and flow rate: Ensure that the purity of the protective gas (such as argon, carbon dioxide, etc.) meets the requirements, the flow rate is appropriate, and avoid porosity or oxidation defects caused by gas quality issues.
● Nozzle design and cleaning: Use nozzles of appropriate size and shape, regularly clean the inner wall and conduit of the nozzle to ensure that the gas covers the weld evenly and smoothly.
5. Welding materials and pretreatment:
● Welding wire selection: Select welding wire that matches the base material to ensure good welding performance and weld quality.
Workpiece cleaning: Remove impurities such as oil stains, rust, and oxide scales from the surface of the workpiece to ensure a clean welding interface and reduce welding defects.
6. Programming and Path Planning:
Welding path: Reasonably plan the starting and ending points, sequence, speed, etc. of welding to avoid cracks caused by stress concentration and ensure that the weld seam is uniform and full.
● Avoid interference: When programming, consider the spatial relationship between the welding gun, workpiece, fixture, etc., to avoid collisions or interference during the welding process.
7. Monitoring and Quality Control:
Process monitoring: Real-time monitoring of parameter changes and weld quality during the welding process using sensors, data acquisition systems, etc., to promptly identify and correct problems.
Non-destructive testing: Ultrasonic, radiographic, magnetic particle, and other non-destructive testing shall be carried out after welding to confirm the internal quality of the weld seam, and repairs shall be carried out for non-conforming welds.
8. Personnel training and maintenance:
● Operator training: Ensure that operators are familiar with welding processes, equipment operation, and troubleshooting, can correctly set and adjust parameters, and promptly handle problems that arise during the welding process.
Equipment maintenance: Regularly maintain, inspect, and calibrate welding robots to ensure they are in good working condition.
Through the comprehensive measures mentioned above, welding defects caused by welding robots can be effectively reduced, and welding quality and production efficiency can be improved. Specific solutions need to be customized and implemented based on actual welding conditions, equipment types, and defect properties.