Spot welding ensures two metals to be combined without the need for any filler and it is used where a continuous welding seam is not required, thus it is used more robotic automation applications day by day due to its fast cycle time, economical production and connection of various materials. Spot welding, also known as resistance welding, is a very suitable robotic welding application for sheet materials.
While welding process may be carried out by moving the welding gun connected to the robot wrist on the workpiece, it may also be carried out by moving the workpiece between the jaws of a fixed welding gun with the robot. The welding gun generally defined as 7th axis of the robot in robotic applications has a pneumatic or servo working system. The jaw structure of the welding gun may be used as X pliers or C pliers in accordance with the workpiece geometry.
Robotic spot-welding applications require knowledge and experience as well as all its advantages. For this reason, the selection of the right robot integrator is very important during the transition to a robotic spot-welding system.
All requests and demands of the customer are collected for the transition to the robotic spot-welding system and the following steps are followed:- The compatibility of the part to be produced is checked for the transition to the robotic system.
- Welding robot is determined which has suitable cycle times, speed and reach for process, through analyzing the parts on the simulation which to be welded.
- If more than one welding robot is required to produce the parts, the system is set up with a line-shaped stations.
- Equipments such as positioner, rotary table, etc. are included in the system for correct welding angles and robot’s need for more access.
- For producing the parts with the same quality and standards, welding fixture is manufactured according to the technical characteristics of the parts and the reach of the robot.
- A servo or pneumatically driven welding gun (plier) is selected to be suitable for welding work that will provide the highest efficiency.
- In addition to the main equipments, other peripheral equipment such as grinding (electrode shaving), automatic electrode changer station are used.
- Electricity, automation and plc infrastructure is created according to the project scope.
- Upon request, the entire system is provided in the welding cabinet or a cell.
- The suitability of the designed system is finalized as a result of the studies conducted with the customer, and the system is formed into its general shape.
- The prepared system is equipped with compatible equipment for occupational health and safety and then it is commissioned.
- After the completion of commissioning process, the system is maintained through after-sales services.
