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BY:
BEREKET ABATE
MEKDIM BOGALE

ADVISOR: MESFIN (MSC)

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CONTENT
 Objective of the project
 Discussion
 automation
 Robotic welding
 Manual welding
 Robot configuration
 The mechanical parts and drive mechanism
 Teach pendant
 Programming the welding robot
 Different controller integration
 Cost analysis

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 OBJECTIVES

 To develop a welding robot for an

operation in MIE due to its high
advantage and benefit it contribute
for the achievement of their
industry vision.

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 MANUAL WELDING
 less productive
 less safety
 less quality
 high hand-eye
coordination

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AUTOMATION AND ROBOTICS

 Uses mechanical, electronic, and

computer based systems in the
operation and control of production
 robotics is a form of industrial
automation.
 Fixed automation, programmable
automation, and flexible automation

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ROBOTIC WELDING

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 ROBOT CONFIGURATIONS

polar configuration cylindrical configuration

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Cartesian configuration
gantry configuration
 THE MECHANICAL PARTS
AND
DRIVE SYSTEMS
 ANALYSIS FOR CROSS SECTION

DESIGN OF BALL SCREW
 MOTOR SELECTION CALCULATION
 DETERMINE THE DRIVE
MECHANISM

DESIGN OF THE COUPLING


BEARING SELECTION
 MOTOR SELECTION AND BALL
SCREW

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 SLIDING BAR
 Support and hold
the moving
components
 Made of Aluminium
 Fixed at both ends
 Each transverse
axis contains two
sliding bars

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 BALL SCREW
 Have higher
efficiency more than
90%
 Inexpensive
 High accuracy
 High load capacity
 Compact size
 Have lower
coefficient of
friction
 Uses lower power
input
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BEARING
 Angular contact
ball bearings are
used for
horizontal ball
screw
 Trust bearings are
used for vertical
ball screw

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STEEPER MOTOR
 Are driven by electric
pulses
 Every pulse rotate the
pulses through a certain
amount
 By counting the pulses,
the amount of motion can
be controlled
 No feedback signal for
error correction
 Cheaper than closed
system

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TEACH PENDANT
 hand-held robot
control terminal
 means to move
the robot, teach
locations, and run
robot programs

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 PROGRAMING THE
WELDING ROBOT
Item
 Displays error messages, status, operator prompts
 Function 1-5 buttons with association displays for menu choices
 Numeric to enter numeric data
 Preview to move to the previous menu level
 Status displays status of overrides
 Halt stops arm motion and puts the system in “halt”

model
 Vert align aligns the tool z axis with the worlds z axis
 Jw w/t selects joints or world/tool motions in manual mode
 Relax relaxes the selected joint

 Speed used to set monitor speed of arm

 Gri p1, 2 used to operate the gripper controls
 Motion switches used to move the joints or the arm in world or tools
mode depending on jt w/t

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 METHODS OF DEFINIG
POSITION IN SPACE

 TEH MODE STP MODE TRANS PTS STIORAGE OTHER


PROGRAM PALLET POINT
 ACCEPT STEP RECORD GROUP OTHER

 MOVE STEP GRIPPER GOSUB OTHER

 MOVE PT (XXXX) SPD (YY) ABC

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 GENRAL ROBOT CONTROLLER
ELEMENT
I/O DEVICE

PROGRAM MATHEMATICAL
EXCUTIVE PROCESSOR
MEMORY PROCESSOR

CONTROLLER CONTROLLER CONTROLLER

1 2 3

POWER POWER POWER

AMPLIFIER AMPLIFIER AMPLIFIER
STEEPER MOTOR and
CONTROLLING BOARD

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POWER SUPPLY and END
EFFECTOR INTEGRATION

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CONT…
 supply the electrical energy necessary for arc welding
processes
 the length of the arc is directly related to the
voltage, and the amount of heat input is related to the
current
WELDING TORCH

 connected to robot
flanges
 The welding robot holds and
manipulates to make the weld

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 SAFETY, TRAINIG,
MAINTENANCE

SAFETY
 Emergency Stops are available on the MAIN
PENDANT and OPERATOR PENDANT.

 In “TEACH mode", the velocity of the robot is

restricted at a safe speed and the robot cannot be
moved on the gantry

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TRAINIG

 Awareness
 Justification
 Application
 Operations and maintenance
 Safety

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MAINTENANCE

 Occasional equipment failures do

occur and periodic maintenance
service is required

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COST
Robot economy analysis form

Project name………………………..prepared by-------------------------- Date--------------

 Investment costs us dollar
 Aluminum cost 100
 Cast iron & steel 200
 Ball screws 50
 Bearing 60
 Motor cost 500
 Teach pendant cost 1200
 Welding torch 127
 Manufacturing cost 560
 Engineering cost 1200
 Controller cost 800
 Miscellaneous cost 400
 operating cost
 Labor cost 623
 Training 700
 Total cost 6520 us$

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CONCLUSIONS
 The easier and faster operation compared to a
conventional robotic system.
 The training time required to use the system
is much shorter than for a conventional
robotic system
 Can be trained to use the system within one
day
 A less hazardous and better working condition
for human

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RECOMENDATION

 This development of robotics looses more

details
 better to done with other concerned
departments like Electrical engineering dept
THANK YOU !!

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