Integrated Design and Manufacturing Lab

Practical No. 10

Date of Performance: 22/03/2017

A report on

Robotic Welding Station

Prepared by Submitted to

Srinath Gudur Dr. Abhay Sharma

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 Robotic Welding Station
Aim: To understand the working of Robotic Welding Station (Twin Wire Gas Metal Arc
Welding, GMAW)
Equipment Name: KR 30-3 Robot, Fronius
Make: Kuka

Introduction: Gas metal arc welding (GMAW), is a welding process in which an electric
arc forms between a consumable wire electrode and the workpiece metal(s), which heats
the workpiece metal(s), causing them to melt and join.

Along with the wire electrode, a shielding gas feeds through the welding gun, which
shields the process from contaminants in the air. The process can be semi-automatic or
automatic. A constant voltage, direct current power source is most commonly used with
GMAW, but constant current systems, as well as alternating current, can be used.

Robots for welding

The term "robot" is derived from the Slavic word "robota", which means forced labour
(see introduction to robotics). The robot itself is nothing more than a programmable
mechanical arm that is controlled from a computer system, the robot controller. A MIG
welding robot holds a welding torch and manipulates this around a work piece in a
similar way as a human welder.

Definition of a robot according to European standard EN 10218-1

A robot/industrial robot is an automatically controlled, freely programmable, multi-

purpose manipulator that can be programmed in three of more axes, is used in
automation systems, and can be either fixed in place or mobile.

The robot consists of:

i. The robot arm (including actuators)

ii. The control device including teach pendant and all communications interfaces
(hardware and software)

This includes all external axes controlled by the robot controller.

The industry standard

The industry standard is a machine with about 1.4 m reach from the centre of the base to
the knuckle joint near the wrist. It is however very useful to have the option of a robot
that has a longer reach. The choice of robot depends on the assembly that needs to be
welded.

The KUKA KR30 L16-2 is an example of a robot with an extremely long reach of 3102 mm.
It would be very unusual to use such a machine, but depending on the application it could
be more economical to use this robot, rather than a standard robot on a track or an
inverted robot that is suspended from a gantry system. An inverted robot will use the top
area of the robot's working envelope and this can be useful if the robot needs to cover an
assembly that is too wide or too deep for a floor mounted robot.

Robots specifically designed for arc welding

Traditional robots are still extensively used for arc welding. However dedicated arc
welding robots have some benefits. The upper arm accommodates the welding hose
bundle. This arrangement offers higher protection to wear and tear compared to the
traditional dressing method where the hose bundle runs over the top of the upper arm.
In addition it facilitates robot programming since the programmer does not need to
consider the hose bundle which could otherwise get snagged up in the assembly or
fixture. A fringe benefit is also that the Tool Centre Point (the reference point for
programming, in this case the end of the welding wire) is more consistent due the better
guided and shorter hose bundle. This in turn can give a quality improvement when
welding conditions are critical.

Robot Axes:

The articulated arm of the robot has 6 degrees of freedom or axes, which are driven by
electric, brushless AC motors from the robot controller. These are referred to as axes 1 to
3 for the major axes and as axes 4 to 6 for the minor axes. On the teach pendant are six
jog keys, which are clearly marked so the user will find it easy to identify the correct one.
The KUKA controller is unique in as much that it features a teach pendant (Smart Pad)
which in addition to the jog keys, has a Space Mouse that allows the user to select any of
the robot axes from a single control knob.
 Fig 1: Robot Axes

A1: base rotation A4: upper arm rotate

A2: lower arm back and forth A5: wrist bend
A3: upper arm up and down A6: wrist rotate
Robotic twin wire GMAW welding is a process whereby two separate power sources
are linked via a high speed local bus communication. The two wires are fed through a
single hose bundle and terminate in a fairly large welding torch with two separate tips
that are set a distance apart. The first wire is responsible for the penetration and is the
limiting factor in what can be achieved in the way of increased welding speed. The second
wire follows behind and is responsible for the fill. Twin wire welding can give very high
deposition rates compared to single wire MIG of up to 30 kg/hr. A limiting factor is the
condition of the parent material and any mill scale, corrosion or contamination will result
in reduced welding speeds.

It is a common misunderstanding to assume that twin wire welding is twice as fast as

single wire MIG. The actual increase in welding speed is about 30% to 40% compared to
a non-optimized single wire MIG welding process. Twin wire welding is a highly
specialized process that should only be considered for large open assemblies with long
joints, typically found in assemblies for earth moving equipment. It requires an additional
level of process expertise from the user and many systems in the field have poor
performance because companies have failed to recognize the need for in depth training.
In practice it is much easier to handle a process with two single wire robots and often this
tends to be more productive. Against this is the higher level of investment required for
two robots and sometimes the total number of cells (and floor space) that are required to meet
a certain output.
 Fig 2: Fronius twin wire welding torch

Benefits of robotic welding:

Productivity

A robot typically works between two or more work stations. This means that during the
robot welding cycle the operator is unloading a welded assembly and then loads new
components to a welding fixture. Because there is less handling compared to a manual
weld cycle the robot achieves much higher levels of arc-on time. The robot also moves
very quickly between the joints and this yields a further saving in cycle time. Typically a
robot system will increase output by a factor of two to four. This depends on the nature
of welding. An assembly with lots of short welds can be produced with the most time
savings. The cost savings that robot welding brings, can help companies to be more
competitive and beat off competition from low cost manufacturing countries in Eastern
Europe or China. In order to assess what sort of productivity improvements can be
achieved it would be appropriate to compare manual welding times with robot welding
times.

Quality

The robot has a very high repeatable accuracy (± 0.04 mm) and excellent path following
accuracy. The robot presents the welding gun at the correct welding angle, welding speed
and distance. The high level of integration to the welding equipment ensures that
optimum welding conditions can be used for each and every joint. The end result is
consistent high quality output, day in day out, year in year with reduced cost for rework,
scrap or removal of weld splatter.

Consumable costs

It is up to the judgment of a manual welder to weld to the correct standard, but often the
weld is oversize. A robot however, always welds to the correct length and size of weld
that it has been programmed to produce. This means that some potential savings in wire
consumption can be made. If for example a manual welder welds a 5 mm fillet, where only
a 4 mm fillet is required, the savings in welding wire alone will be a staggering 36%!
Labour

In recent years it has become increasingly difficult to employ manual welders. There
tends to be a certain amount of staff turnover and this of course carries a cost for
recruitment and training. When labour is an issue companies often find themselves
working overtime or having to employ additional contract labour to meet demands and
this can have a serious impact on production costs. If products cannot be supplied to the
end customer, penalties may be incurred or future business may be at risk. Whilst there
will always be a requirement for manual welding, companies that invest in robotic
automation are much less dependent on manual welding.

Safety

A robot welding system addresses health and safety issues associated with dangerous
welding fumes and exposure to arc-flash. Companies can reduce the risk of their
employees claiming compensation if they are affected by the hazardous working
environment.

Flexibility

The robot can be used to weld many different products and allows companies to consider
Just In Time production. By reducing work in progress and stock levels, savings can be
made due to fact that less value is added to stock levels in terms of labour, transport and
storage costs.

Specifications of KR 30-3 F:
KR 30-3 F
Category Medium Payloads (30-60 kg)
Construction type Standard
Extension 1 Standard
Extension 2 Standard
Version environment Foundry
Environment version extension Standard
Payload 30 kg
Total load 65 kg
Maximum reach 2033 mm
Number of controlled axes 6
Position repeatability ±0,06 mm
Weight 635 kg
Mounting positions Floor
Ambient temperature 10 °C to + 55 °C
Controller KR C2
Protection class IP 64
Protection class inline wrist IP 67
 Axis Range of motion software—limited Speed
1 ±1850 140 0/s
2 +350 to -1350 126 0/s
3 +1580 to -1200 140 0/s
4 ±3500 260 0/s
5 ±1190 245 0/s
6 ±3500 322 0/s

Fig 3: Twin wire robotic welding setup

On-line programming

The vast majority of arc welding robots are programmed on-line using a teach pendant.
This will feature a joy stick or a series of toggle or jog keys to select which way you wish
to move the robot to an intended position. With the KUKA SmartPad the user has the
additional option to use the 6 axes Space Mouse. Each position is recorded with the
appropriate instructions relating to the accuracy of the position, the type of robot move
plus any additional process related information.

Robot programs can be given logical names so it easy to select the correct one afterwards.
Whilst most robots will have their own unique way of being programmed, the basic
principle is the same.

The teach pendant

All functions are available from the teach pendant. Commands are selected from a list and
are very easy to understand. The user does not have to worry about machine codes or
syntax. The only function on the actual robot control cabinet is a rotary on/off switch. The
layout is straight forward and the user can make selections on the colour touch screen
and the key pad.

The user can select in which way the robot moves to this position, either in a polar
coordinate system moving each robot axis individually or in a linear coordinate (or
Cartesian) system whereby the robot moves in X,Y and Z describing a straight path at the
Tool Centre Point. The latter is an obvious requirement when programming a straight
joint for welding. When programming the robot, "teach" is selected and this drops the
robot speed to safe levels of 250 mm/sec. In order to move the robot a three position
dead man's handle located on the teach pendant, needs to be held in the middle position
to release the brakes and supply power to the motors. The jogging and run speed of the
robot can be altered to suit when a toggle key is pressed. The key switch is rotated to T1
to T2 to test the program at 100% speed with the dead man’s handle still activated or in
Automatic or Automatic Extended when running the robot in normal production mode.
When the robot is run in automatic mode, the teach pendant can be parked in a safe place
on the robot control cabinet and in case of the KUKA SmartPad teach pendant it may be
removed from the system completely.

The programmer will generally have a number of choices to achieve certain programming
objectives. Large programs can be split up into sub-programs and this will make it easier
to recognize them and make modifications afterwards. Similar parts of a robot program,
e.g. welding round a series of bosses can be copied or repeated with a shift function.
Circles can be programmed with only 3 points, but it is also possible to specify a radius
from the center position. Entire programs can be shifted to another workstation using a
base coordinate system.
 Fig 4: The teach pendant
1. Button for disconnecting the smartPAD.
2. Key switch for calling the connection manager. The switch can only be turned if
the key is inserted.
3. EMERGENCY STOP button. Stops the robot in hazardous situations. The
EMERGENCY STOP button locks itself in place when it is pressed.
4. Space Mouse: For moving the robot manually.
5. Jog keys: For moving the robot manually.
6. Key for setting the program override
7. Key for setting the jog override
8. Main menu key: Shows the menu items on the smartHMI
9. Status keys. The status keys are used primarily for setting parameters in
technology packages. Their exact function depends on the technology packages
installed.
10. Start key: The Start key is used to start a program.
11. Start backwards key: The Start backwards key is used to start a program
backwards. The program is executed step by step.
Keyboard key displays the keyboard. It is generally not necessary to press this key to
display the keyboard, as the smartHMI detects when keyboard input is required and
displays the keyboard automatically.

Different robot moves for programming

The robot programmer tends to only use three commands to program robot movements,
which are point to point move (PTP), linear move (LIN) or circular move (CIRC). On the
KUKA SmartPad teach pendant these are defined as follows:

PTP Move

1) Motion type. Select PTP, LIN or CIRC

2) The name of the end position
3) The end point is approximated. If left blank the motion stops exactly at the end point
4) Velocity. PTP motions: 1 … 100%
5) Motion data set: acceleration and approximation distance if CONT is entered under 3
LIN Move

As for PTP move except:

4) CP motions: 0.001 to 2 m/s

CIR Move

As for PTP move except:

2) In the case of CIRC, an auxiliary point must be taught in addition to the end point
4) CP motions: 0.001 to 2 m/s
Tool Centre Point - essential reference point for programming

The TCP is the reference point that is used to program the robot. For MIG/MAG welding
this is the end of the welding wire as it protrudes from the welding gun. This distance is
usually 10 to 12 mm. It is important that the TCP is calibrated accurately to ensure that
the robot visits the joints correctly. If the TCP goes out of alignment (due to e.g. a collision
or if you mount a different type of welding torch), a new TCP can be defined very easily
with only four reference positions around a pointer. It is also possible to calibrate the TCP
by declaring the X, Y and Z values relative of the flange of the robot using the teach
pendant.

Operating Procedure:

1. Switch on the MCB

2. Turn ON knob of teach pendant controller and wait for some time to

initialize the teach pendant then put it in manual mode (T1).

3. Switch ON on the MCB of robot and power source controller. Turn ON the

knobs of master and slave controllers

4. Turn ON the inert gas supply (Argon 80% and Carbon 20%)
5. Set the parameters in Master and Slave Controller. Following parameters were set
during the welding:
a. Current - 160 ampere
b. Voltage – 24.5
c. Wire feed – 16.4 m/min

(Actually all these 3 parameters were synchronized. When we change Current

automatically the other two values were adjusted)

6. Start doing the programming. The programming is to be done in T1 mode only

7. Select New
8. Do the programming between the two lines of homing position (Line No.3 and 5)
9. Perform Safe positioning procedure
10. Go to Motion Mode. Select the required movement PTP, LIN/CIRC command. Teach
the torch for the movements required
11. Go to Technology Mode for Arc ON and Arc OFF
 12. After the editing program, RESET once and then rotate the knob to (T2) mode for
dry run. In dry we check only the execution of program.
13. Then Select (T3) mode for automatic operation. The arc becomes ON during
welding and becomes OFF once the welding is finished

Results:

A single pass Weld bead is prepared on the given work piece of Steel using robotic twin
wire GMAW