1、 Inspection and maintenance of welding robots

1. Wire feeding mechanism. Including whether the wire feeding force is normal, whether the wire feeding tube is damaged, and whether there are any abnormal alarms.   

2. Is the airflow normal?   

3. Is the torch safety protection system functioning properly? (Prohibit turning off welding gun safety protection work)

4. Whether the water circulation system is working properly.   

5. Test TCP (it is recommended to prepare a test program and run it after each shift)

2、 Weekly inspection and maintenance of welding robots

1. Clean the axis of the robot.

2. Check the accuracy of TCP.   

3. Check the oil level of the residue.

4. Check if the zero positions of each axis of the robot are accurate.

5. Clean the filter behind the welding machine oil tank.

6. Clean the filter at the inlet of the compressed air.   

7. Clean the impurities at the cutting torch nozzle to avoid blocking the water circulation.

8. Clean the wire feeding mechanism, including the wire feeding wheel, wire pressing wheel, and wire guide tube.   

9. Check whether the hose bundle and guide wire hose are damaged or broken. (It is recommended to remove the entire hose bundle and clean it with compressed air.)

10. Check if the safety protection system of the cutting torch is working properly and if the external emergency stop button is functioning properly.

3、 Monthly inspection and maintenance of welding robots

1. Lubricate the axis of the robot. Among them, axes 1 to 6 are white with lubricating oil. Oil number: 86E006.   

2. RP locator and red nozzle on RTS rail with butter. Oil number: 86K007

3. Blue lubricating grease and gray conductive grease on the RP locator. Oil number: 86K004

4. Wire feeding needle roller bearings with lubricating oil. (A small amount of butter can be used)

5. Clean the spray gun device and fill it with air motor lubricant. (Ordinary engine oil is sufficient)

6. Clean the control cabinet and welding machine with compressed air.

7. Check the cooling water level of the welding machine oil tank and replenish the coolant in a timely manner (pure water with a little industrial alcohol)

8. Complete all weekly inspection items except for tasks 1-8.

With the rapid development of intelligent technology, spraying robots have been widely used in various industries. The spraying process and suitable products of spraying robots are different. Below, the editor will introduce three spraying methods of spraying robots.

1. Electrostatic spraying method: Among these three spraying methods, electrostatic spraying is the most widely used spraying method for spraying robots. Its spraying principle is mainly based on the grounded sprayed workpiece as the anode, while the coating atomizer is connected to a negative high voltage as the cathode, so that the atomized coating particles are charged and adsorbed on the surface of the workpiece through electrostatic action. The electrostatic spraying method used by spraying robots is often used for metal spraying or spraying workpieces with complex coating structures.

2. Air spraying method: The air spraying method of the spraying robot mainly uses the airflow of compressed air, which flows through the nozzle hole of the spray gun to form negative pressure. Then, under the action of negative pressure, the paint is sucked in and sprayed evenly on the surface of the workpiece through the spray gun, forming a smooth coating. The air spraying method of painting robots is generally used for painting workpieces such as furniture and electronic casings. And due to the low production cost of air spraying method, it is still widely used among the three spraying methods of spraying robots.

3. High pressure airless spraying method: Compared with air spraying, the high-pressure airless spraying method of spraying robots is a more advanced spraying method. It mainly uses a booster pump to pressurize the paint to a high pressure of 6-30MPa, and then sprays it through the fine pores of the spray gun to atomize the paint. The high-pressure airless spraying method has high coating utilization and spraying production efficiency, and the quality of workpieces sprayed by spraying robots using high-pressure airless spraying method is significantly better than that sprayed by air spraying method. The high-pressure airless spraying method is generally suitable for spraying workpieces with high requirements for coating quality.

In order to enable the welding robot to work efficiently and ensure its normal operation, users need to regularly maintain and inspect the robot body and system after using the robot for a predetermined period of time, while also ensuring the safety of equipment and personnel during operation. The robot should undergo a spot check every 4000 hours (or more than two years) of operation. It is recommended that users hire welding robot professionals for inspection.

1、 Inspection of the main body of the welding robot

1. The robot body and control box are equipped with lithium batteries for servo motor encoder data backup. The service life of the battery varies with the working environment. When it exceeds two years, the battery needs to be replaced, otherwise the motor encoder data will be lost and the origin adjustment needs to be carried out again. Before replacement, it is necessary to backup the teaching data to prevent the loss of teaching programs and set parameters.

2. Are the axis marks at the origin aligned.

3. Check whether the operation of each axis is smooth and stable during automatic and manual operation.

4. Whether the robot safety switch and emergency stop switch are normal.

5. Whether the wire feeding mechanism is stable.

6. Whether the deceleration mechanism is worn.

7. Adjust the elasticity of the toothed belt.

8. Add lubricating oil to the TW, BW, and RW axles (ordinary butter is not allowed to be added to the oil holes).

2、 Control box inspection

1. Lithium battery replacement.

2. Check the cooling fan.

3. Cable inspection (grounding cable, power cable, control cable).

4. Are the switches on the control panel of the teaching pendant functioning properly.

5. Dust removal inside the control box.

3、 External axis and positioning fixture inspection

1. Lithium battery replacement.

2. Add lubricating oil.

3. Whether the connecting bolts are tightened.

4. Are there any abnormalities during runtime.

5. Check if the locating pin is worn.

4、 Welding machine section

1. Welding power supply (internal dust removal, whether the connection parts are loose).

2. Welding gun (nozzle cleaning, whether the wire feeding tube is blocked, whether the insulation is normal, whether the gas pipe is leaking, whether the cable is loose or damaged).

3. Wire feeding device (whether the wire feeding wheel is worn, whether the SUS tube is damaged or worn, and whether the wire feeding motor is abnormal).

4. Grounding cable (whether there is burn damage, cracking, and whether the connection is tight).

Feasibility analysis of welding robots. Consider whether the welded parts are standard parts, whether the welding thickness meets the welding requirements, welding quantity, etc.

2. Selection of specialized or universal welding robots. If the user only welds the same type of welding parts for a long time, specialized welding equipment can be considered; If multiple welding components need to be welded, more universal automatic welding equipment can be considered.

3. Adhere to the principle of "applicability is the best". For example, when performing straight seam welding, using a 6-axis robot for long-term welding may be a bit overcorrected.

If the welding process parameters are unknown, the welding effect and efficiency can be verified through trial welding.

5. For price, users can compare prices from three different sources. For the welding requirements of the same product, if there is a significant price difference between equipment from different manufacturers, it can be balanced from the aspects of mechanical configuration, manufacturer strength, after-sales terms, welding efficiency, etc.

If the user encounters a certain type of welding component, they need to first confirm whether it can achieve automated welding. Even if it belongs to the same product, if the cutting method and thickness are different, others can achieve automated welding, but it does not mean that you can also achieve it. The production of argon arc welding automatic welding equipment and molds relies on long-term accumulated welding technology experience. The same equipment may have different levels of training, debugging, and after-sales service for different personnel, resulting in varying final usage effects.

What is the speed of the welding robot during the welding process?

According to specific welding specifications, welding wire models, and other parameters, when using 4.0 specification welding wire for submerged arc welding, the general welding speed is 350-500mm/min, which is 35-50cm/min.

Welding robot is an automation equipment based on motor control technology, microcontroller control technology, PLC control technology, and digital control technology. Welding robots are mainly used for automatic loading and unloading of workpieces, automatic conversion mechanisms for workpiece workstations, automatic clamping mechanisms for workpieces, automation systems for workpiece welding processes, and system integration control.

The paint flow rate of a spraying robot is the amount of paint delivered to each rotary cup per unit time, also known as the spraying flow rate or paint output rate. So how is the paint flow rate calculated?

In addition to the rotational speed of the rotary cup, the coating flow rate is the second factor that affects the fineness of atomized particles. When other parameters remain constant, the lower the coating flow rate, the finer the atomized particles, but at the same time, it can also lead to an increase in solvent evaporation in the paint mist.

A high flow rate of paint in the spraying robot will form a wavy coating. At the same time, when the paint flow rate is too high and the rotary cup is overloaded, the coating on the edge of the rotary cup thickens to a certain extent, causing the grooves and patterns on the rotary cup to prevent the paint from flowing and resulting in layered paint, which can cause adverse phenomena such as bubbles or uneven droplet sizes.

The paint flow rate of each spray gun of the spraying robot is related to the diameter and speed of the high-speed rotary cup, as well as the density of the paint. Its upper limit is determined by the fineness of atomization and the effect of electrostatic coating. Practical experience has shown that coatings should be input at a constant speed, and fluctuations within a small range will not affect the quality of the coating film.

In the actual spraying process, the spraying robot sprays different areas on each rotary cup, and the flow rate of the coating is also different. In addition, due to changes in the shape of the object being coated, the flow rate of the coating on the rotary cup also changes. Taking the spraying of car bodies as an example, when spraying large areas such as door panels, the amount of paint sprayed should be large, while when spraying door pillars and window pillars, the amount of paint sprayed should be small. Only by automatically and accurately controlling the amount of paint sprayed during the spraying process can the quality and thickness of the coating be ensured, which is also one of the important measures to improve the utilization rate of the coating.