Automate MIG Welding operation in a Robotic cell.
Tags: Robotics, Robotics Technology, Welding, Robotics Automation, Kuka Welding Robot

An overview of MIG Welding operation performed using 8-axis KUKA Robotic Cell

Figure 1 : KUKA MIG welding Robotic Cell

Welding provides higher tensile strength, shear strength and durability to the structure. Welding is a manufacturing process in which two or more parts are fused together by means of heat, pressure or both of which form a joint as cool parts. The finished welded joint can be referred to as welding. Welding applications are widely used for building bridges, ships, cars, and large monumental structures, etc. We will identify them on the basis of their working theory, after knowing the intent of welding. Two types of welding operations are available, Fusion Welding and Solid State Welding. Fusion welding is a method in which metal joining is done by supplying heat, through chemical or electrical energy, to the melting point of the metal. It is also called non-pressure welding as well. In this article, for instance, we will learn more about how to automate MIG welding, TIG welding, Arc welding, etc. This article will focus on MIG Welding and how we can automate welding operations.

What does MIG Welding mean?

Image from Weld Guru

MIG welding is a welding process of the fusion form, where the heat of an electric arc between an electrode and the workpiece completes the joining of metal. We are using a shielding gas for Kuka Robot MIG Welding, which consists of the following elements: Argon, Helium, Carbon Dioxide and Oxygen. Shielding gas shields oxygenation as well as impurities and moisture in the air from the solidifying molten weld. If the weld, this situation will cause corrosion resistance, which will affect welding accuracy.

2. What are the components used to complete a Robotic cell?

1. 6 — axis KUKA Robot Arm ( KR16 R2010 )

2. KempArc Pulse 450

3. KRC4 controller

4. Wire feeder DT 400L

5. Torch cleaning Tbi BRG-2.

6. Linear track KL250

To make MIG welding possible, every component has a particular purpose. The robotic cell is a Kuka Robot 8-axis MIG welding cell with two additional external linear axes called Linear track KL250. An additional two axes increased the rate of output and also provided multitasking tasks in a single cycle. I would now like to expand further on the 6-axis KUKA Robot Arm (KR16 R2010) and 2 additional linear-axes for improving the mobility of the robotic arm and improving the performance, accuracy and precision of welding a metal work piece.

3. A 6 — axis KUKA Robot Arm ( KR16 R2010) :

Specifications of 6 — axis KUKA Robot Arm ( KR16 R2010)

The term robot is described, according to the International Organisation for Standardisation (ISO), as an automatically operated, reprogrammable, multi-purpose manipulator that can be programmed into three or more axes, either fixed in place or mobile for Industrial Automation use. Robotic manipulators are able to execute routine functions with greater precision and accuracy, expanding the production and manufacturing capacity of companies. Robots that run in their common space using servo motors, but tasks are described and objects in Cartesian Space are manipulated.

The representation of the kinematics of each robot is divided into two groups, namely Forward Kinematics and Inverse Kinematics. The transformation of a robot from a joint space coordinate to a cartesian space coordinate is known as forward kinematics, i.e. if we know the position of each joint space, then the end effector will be at the joint space position respectively. Inverse kinematics can be defined as the conversion from Cartesian space to joint space, i.e. where the end effector moves according to the delivered data, the joint space is determined by the robot making the end effector set according to the requirement.

In the figure 1, KR16 R2010, the KUKA Robot that we use for welding purposes, which is read as Kuka Robot where 16 Kg is the capacity of the robot payload, is known as payload, the maximum weight a robot can withstand. R2010, which is 2010 mm, is its reachability. This robot has 6 degrees of freedom, making the welding process more efficient. The end effector is connected with a welding gun where the shield gas for melting metals is heated up to very high temperatures. The other two linear axes, known as the Linear Track KL250, make welding more convenient. These two axes have a rotational motion that is that it has only one degree of freedom, to perform multiple operations in a single cycle, the motion is given to those axes. The goal of attaching these two axes is to increase the production rate, reduce the production time for the single work piece, and properly use shielding gas without gas wastage.

For more details on the use of 8 — axis MIG Welding Robotic cell. Read my paper on — MIG WELDING USING 8-AXIS KUKA ROBOT

DOI : Click here to download paper