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Advances in Welding Technology
Fundamental changes to the way welding is done provides shops with faster, more flexible software, equipment and solutions. The post Advances in Welding Technology appeared first on Fabricating & Metalworking.
Digitalization and data-driven welding, coordinated motion at work in cobotic welding, and unique features and capabilities such as blue diode lasers, are creating enhanced and new opportunities for metalworkers.
Blue Laser Tech Added to Suite of Micro Welding Tech
AMADA WELD TECH (Monrovia, CA) has integrated cutting-edge blue laser technology into its suite of micro welding technologies. Blue diode lasers deliver superior performance in welding highly reflective materials, notably copper. AMADA WELD TECH’s blue laser systems offer power levels ranging from up to 1,500 watts, and with capabilities extending up to 4,000 watts for industrial applications.
Feasibility studies can be run in the company’s Western Technical Center in Monrovia. The capability in the technical center includes power levels up to 1, 500 watt and spot sizes between 200-to-500 microns in diameter. This enables precise joining of delicate components, making it ideal for applications in the electronics, medical devices and automotive industries. The unique wavelength can also be used for other applications.
Communication Tech Enables Changes Without a Control Cable
ESAB’s (North Bethesda, MD) RobustFeed AVS ECHO voltage-sensing wire feeder is a new communication technology that allows voltage adjustment at the feeder without a communication/control cable to the power source. The new feeder uses the weld cables to transmit voltage data to the Warrior® series of power sources (400i, 500i or 750i) outfitted with the required ECHO upgrade kit. The system performs a measurement on the first weld and compensates for any losses that occur in the welding circuit for all the subsequent welds.
“Compensating for voltage drop improves accuracy when using long cables, which is common in offshore, railcar, ship/barge, construction and repair and maintenance applications,” said Catalin Toma, global product manager – heavy industrial products, ESAB. AVS-style feeders eliminate the need for a communication/control cable between the power source and the feeder. The design simplifies cable management in portable applications, eliminating a cable that could potentially get damaged.
The front panel of the RobustFeed AVS ECHO features voltage and amperage controls and digital meters visible in all light conditions, 2T (standard) or 4T (trigger lock) control, gas purge, wire jog, CC/CV mode switch and an optional internal gas flow meter protected by the rugged case. The feeder also has an IP54 protection rating.
The feeder also has three crane-certified handles and two additional lifting points for best-in-class portability and maneuverability. Additionally, where other portable feeders only have a 2-wheel drive, this feeder uses a 4-wheel drive mechanism and encoder-controlled feeding for precision feeding.
High-end Software Offline Programming System
Pemamek LLC’s (Mason, OH) software offline programming system, WeldControl 300, offers the newly released AutoScan and PathPlanner features. The WeldControl 300 is an operating system for heavy robotic welding automation. Integrated into all robotic welding solutions, the software facilitates offline programming and simulation of robotic welding operations.
PathPlanner revolutionizes welding path planning by automating the creation of collision-free paths. This tool enhances the effectiveness of offline programming and addresses a traditionally time-consuming part of the welding process. It also allows welders with less experience in programming to easily create welding paths. PathPlanner also optimizes robot movements seamlessly from approach to welding to exit, ensuring an effortless workflow on even the most complex workpieces. Its compatibility with existing 3D models ensures easy integration, paving the way for advanced welding automation.
AutoScan enables adaptive automated welding with minimal user input. AutoScan creates data-driven, highly accurate welding paths that can then be used on all subsequent workpieces. As a part of the PEMA Core family of software systems, AutoScan is fully compatible with PEMA FMS. Scan once, all done.
Coordinated Motion: A New Era in Robotic Welding
THG Automation LLC (Indianapolis, IN) demonstrated multi-axis robotic welding capabilities at FABTECH 2024. Featured was a dual-axis skyhook with a part welded by a Universal Robots’ cobot mounted on a rail, all working in unison. According to the company’s website, the groundbreaking coordinated motion technology “empowers multiple robot axes to collaborate seamlessly, executing intricate weld paths with precision and efficiency. By enabling synchronized movement of multiple robot axes, coordinated motion facilitates complex welding tasks on curved, intricate, or multi-dimensional surfaces. This innovative approach enhances productivity, reduces cycle times, and ensures superior weld quality, even on the most challenging geometries.” Coordinated motion in robotic welding is expected to boost productivity in industries such as automotive and aerospace, as well as create new opportunities.
Smart Pendant Software Package Streamlines Programming
Yaskawa America Inc. (Dayton, OH) has launched Weld Builder, a new smart pendant software package designed to streamline the welding programming process for robot integrators and end users. Weld Builder’s user-friendly interface features a step-by-step guided process for creating weld jobs through the Weld Wizard. This intuitive tool helps users, especially those new to robot welding, by guiding them through their first weld job by selecting appropriate welding parameters. The software also includes a Weld Advisor, which, in conjunction with the Weld Wizard, suggests potential welding parameters based on user-defined welds, offering a valuable starting point for robot travel speed and weld parameter data entry.
Weld Builder simplifies the creation of weld jobs with an updated interface derived from Yaskawa’s standard INFORM software, which promotes seamless interactions while maintaining the versatility to address complex welding tasks.
Weld Builder also includes a comprehensive Training Center with detailed instructions on setup and usage as well as general knowledge on robot welding. Additionally, Weld Builder produces standard INFORM jobs, which allows experienced users to modify or enhance weld paths, including advanced features like basic weaving and stitch welding. Weld Builder requires Smart Pendant version 4.0.2 and is compatible with the YRC1000 controller.
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