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Automatic Welding Robot Production Line Full Guide

Welding robots are one of the most widely used industrial robots in the sheet metal industry, accounting for about 40% to 60% of the total robot applications in the world.

The use of welding robot is a revolutionary progress in automatic welding processing. It breaks through the traditional rigid welding mode and develops a new flexible automation mode.

1. Why choose automatic welding robot?

Automatic welding robot

The application of welding robots can not only stabilize and improve welding quality and production efficiency, but also reduce the welding process requirements for welding workers, shorten product upgrade preparation time, and reduce equipment investment.

Robot welding breaks through the traditional rigid welding method and is a new flexible automation method.

When the welding robot completes a welding task, we only need to teach it once, and it can accurately reproduce each step of the teaching operation. If you want the robot to do another job, you don't need to change any hardware, just teach it again.

Therefore, in a welding robot production line, several kinds of weldments can be produced automatically at the same time.

Moreover, using welding robot to replace manual welding is the development trend of welding manufacturing industry. This can improve welding quality and productivity, and reduce costs. On the other hand, the welding environment is relatively bad, which brings certain work difficulties to workers, so the emergence of welding robot solves this problem.

2. Advantages of welding robot production lines

Welding robot production lines

As one of the important symbols of the development of modern manufacturing technology and the development of emerging technology industries, welding robots have been recognized by the world. It has had a significant impact on the lives of people in all fields of the modern high-tech industry.

What are the advantages of welding robot production line? Welding robots offer many advantages. It can be used in various fields to improve production efficiency, stabilize the welding quality of products, improve the competitive advantage of products, and help enterprises achieve transformation and upgrading.

With the continuous improvement of the level of industrial automation, welding robots are more and more widely used in various fields, involving the automotive industry, machinery manufacturing, hardware and building materials, fitness equipment, coal mining, etc. In many modern production workshops, welding robot assembly lines have appeared. Let's take a look at the advantages of an automatic welding robot production line.

The welding robot production line is a production line that connects multiple workstations with workpiece conveying. The automation level of this production line is relatively high. After the weldment enters the production line, no human intervention required, and the welding work can be completed automatically.

- High production efficiency

The operator only needs to arrange the work of the automatic welding robot of each machine position according to the parameters of the weldment and the length of the production line. Then, input the parameters into the control system, and the automatic welding robot production line can realize automatic welding of weldments. 

The product cycle is clear. It is easy for factories to control production efficiency. The production rhythm of the robot is fixed, so the production plan is very clear. Greatly improve the speed of the production line and improve the production efficiency of the enterprise.

Welding robot can work continuously 24 hours a day. With the application of high-speed welding and narrow gap welding technology, the efficiency of robot welding will be improved more obviously.

- High welding quality

Automatic welding robot production line can realize automatic recognition of welds. The welding parameters of each seam are constant when using robot welding. The weld quality is less affected by human factors, so the weld quality is relatively stable.

Through the assembly line work, the production line can strengthen the quality of the weld and put down appropriate welding materials to weld. The weld is beautiful and firm to ensure the welding quality.

- Improve the working environment

Robot welding is used to keep welders away from welding arc, smoke, splash and high temperature. For spot welding, the welder will no longer carry heavy manual welding tongs, which will free the welder from high-intensity physical labor.

- Help enterprises realize transformation and upgrading

In many automobile production workshops, automatic welding robot assembly lines can be seen everywhere, ranging from automobile parts to automobile chassis and frame. In the modern era of rapid development in the automotive field, automatic welding robots help the automotive field achieve diversified development and help enterprises transform and upgrade.

With the rise of labor cost, automatic and intelligent production in construction machinery industry has become the general trend. As the basic process of structural parts production, welding has experienced the process of manual welding, semi-automatic welding and robot welding.

The process is gradually mature, in which the welding robot technology integrates the knowledge of many disciplines such as machinery, electronics, sensors, computers and artificial intelligence. It has experienced three stages: teaching reproduction, off-line programming and intelligent robot.

It is especially suitable for multi variety and small batch flexible production. Through technological innovation to improve the working environment, the operation process is simplified and the application is more convenient.

The expansion and wide application of welding robot in the field of construction machinery has greatly improved the overall production efficiency, improved the working conditions of welding workers, and improved the flexibility level of welding production and welding quality. At the same time, it also promotes the automatic upgrading of welding related fields. "One person, one station" welding is gradually transformed into "One person, One line" welding production.

3. Composition of welding robot workstation

Composition of welding robot workstation

Welding robot is a modern and automatic equipment integrating machinery, computer, electronics, sensors, artificial intelligence and other aspects.

Welding robot is mainly composed of robot and welding equipment. The robot consists of the robot itself and the control system.

The welding robot is mainly composed of manipulator assembly, control system, display and education system, welding machine, wire feeding mechanism, welding gun, etc.

In addition to the welding robot, the welding robot workstation also includes many auxiliary equipment, such as ground rail, positioner, turnover table, weld tracking system, safety fence, gun cleaner, safety system, peripheral equipment and so on. Just a simple set of welding robot, the price is relatively cheap, while the price of welding robot workstation is relatively high.

- Robotic manipulator

Receive the signal from the control cabinet to make the welding grab reach the welding position, etc.

- Control cabinet

Receive external signals, such as welding teaching pendant and external control cabinet, and transmit the data to the robot to complete the welding task.

- Welding gun

The welding gun uses the heat generated by the high current and high voltage of the welding machine to gather at the terminal of the welding gun and melt the welding wire. The melted welding wire penetrates into the part to be welded. After cooling, the welded objects are firmly connected into one.

- Power supply

The high-temperature arc generated by the instantaneous short circuit between the positive and negative poles is used to melt the solder and the material to be welded on the welding wire, so as to combine the objects to be contacted.

- Wire feeder

Under the control of microcomputer, it can continuously and stably send out the welding wire according to the set parameters.

- Positioner

The motor drives the weldment to rotate and pause to make the weldment reach the appropriate welding position. To assist the completion of welding, controlled by the external control cabinet.

- Cleaning station

Completes the cleaning of the welding slag from the welding gun. Spray anti-splash fluid. Trim the wire. To achieve the best welding effect.

- Welding fume purifier 

Welding fume purifier is used for the purification of fume and dust generated in welding, cutting, grinding and other processes, as well as the recovery of rare metals and precious materials. Purify a large number of fine metal particles suspended in the air that are harmful to the human body.

4. How to select the welding robot production line?

Different kinds of welding robot

Choose a welding robot that conforms to the structure of the production line.

According to the welding process, select the load-bearing of the end of different welding robots.

According to the welding quality and production efficiency, select the appropriate welding operation range and technical performance parameters to meet the requirements of the workpiece welding robot position.

On the premise of meeting the production scale, production cycle and guaranteeing the quality of robot welding, the process design scheme must be refined, feasible and economical.

For key components, positioning and important process positions, the number of welding robots can be selected as needed. The welder robot can be adapted to different uses because of its end connection flange.

Welding robots are easy to achieve the stability and improvement of welding products and ensure their uniformity. It can achieve 24h continuous production and greatly improve production efficiency. It can replace manual work in harmful environment for a long time. Relatively reduce the requirements for the technical difficulty of workers' operation. It can shorten the preparation period for product modification and replacement, and reduce the corresponding equipment investment.

With the continuous improvement of manufacturing automation and intelligence, industrial robots are developing rapidly. In the field of processing and manufacturing, the application of industrial robots is becoming more and more mature. Robot welding not only injects new development power into industry, but also will make industrial robots develop more vigorously.

Welding robot can easily replace manual welding for perfect welding. It has a high degree of freedom and can program freely to complete the work of full automation. The use of robot welding can improve the labor intensity of workers and replace many complex jobs that are not suitable for manual completion and harmful to health.

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