ROBOTIC WELDING CELLS
“Materials are changing—whether for the auto indus- try to lighten cars or to meet more stringent rules for rust prevention. Alloys are getting thinner and harder to weld with coatings like galvanneal and hot-dipped galvanized that complicate the welding process,” said Howell. “In addition, customer expectations are for welds that are free of spatter, cleaner, and more uniform.”
Today, the key driver in turning to robotic welding cells is the lack of skilled welders available to fi ll the requirements of shops both large and small.
For welding thinner, harder metals, ESAB’s Swift Arc
Transfer (SAT) high-feed wire process produces deep weld penetration with uniform wide bead profi le. “Our travel speeds are so high that we’re actually reducing the heat
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input and, in turn, producing better parts with less weld distortion and less spatter due to heat,” said Howell. To meet the increasing demand for welding aluminum and thin exotic alloys, ESAB’s dual-process Super Pulse is designed to provide “a really fl exible solution to controlling the arc by modifying parameters on the foreground and background for welding thin exotic metals,” said Howell. “We can set up a duration of time for foreground and background and then we can control whether it’s pulse-pulse, pulse-short arc, pulse- spray arc, short arc-short arc, short arc-spray arc, and vary the duration of time for each process,” said Howell. To develop procedures and programming for its custom-
er’s robot cells, ESAB works closely with its robotic partner in North America, KUKA Robotics Corp. (Shelby Township, MI). “We partnered with KUKA because of the simplicity of the KUKA KRC4 fourth-generation controller,” said Howell. “Anybody can program a robot if you make it easy enough and KUKA has done just that with their KRC4 controller. Teaching somebody to weld is a lot harder than teaching
“Everything for EDM” 76
AdvancedManufacturing.org | October 2015
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