NEW PRODUCT –
Bernard Conventional Liners
Compatible with BTB Semi-Automatic MIG Guns and Legacy Q-Gun, S-Gun, & T-Gun Series MIG Guns
Launched on June 2, 2014, the new Bernard® conventional liners are compatible with all legacy Q-Gun™, S-Gun™ and T-Gun™ MIG guns and all BTB platform guns, which allows you to simplify and reduce your inventory. The image to the right shows how the previous liner locks were merged in the design of the new Bernard conventional liner to maximize backwards compatibility.
Due to this customer-friendly backwards compatibility, the part numbers below supersede previous Bernard conventional liner part numbers.
Made of high carbon music wire for smooth wire feed and long life, Bernard conventional liners are available in lengths of up to 25 feet (7.6 m) and are color coded for your convenience to indicate a variety of wire sizes. Please see the chart below for part numbers, wire sizes, and color coding information:
New Bernard Conventional Liners
| Wire Size | Liner Color | 15′ (4.57 m) | 25′ (7.62 m) |
|---|---|---|---|
| 0.023″-0.030″ | Yellow | L1A-15 | L1A-25 |
| 0.030″-0.035″ | Green | L2A-15 | L2A-25 |
| 0.035″-0.045″ | White | L3A-15* | L3A-25* |
| 0.045″- 1/16″ | Red | L3A-15** | L4A-25** |
| 5/64″ | Blue | L6A-15 | L6A-25 |
| 3/32″ | Grey | L7A-15 | L7A-25 |
| 7/64″-1/8″ | Black | L8A-15 | L8A-25 |
*Standard Liner for 0.035″-0.045″ Guns
**Standard Liner for 1/16″ Guns
Bernard and Tregaskiss Conventional Liner to New Bernard Conventional Liner Cross Reference Chart for Bernard Semi-Automatic MIG Guns
| Wire Size | Bernard Liner Part Number | Tregaskiss Liner Part Number | New Bernard Conventional Liner Part Number |
|---|---|---|---|
| 0.023″-0.030″ | 43015 | 415-23-15 | L1A-15 |
| 0.030″-0.035″ | 43015 | 415-30-15 | L2A-15 |
| 0.035″ – 0.045″ | 44115 | 415-35-15 | LS3-15 |
| 0.035″- 0.045″ | 43115 | — | L3B-15 |
| 0.045″ – 1/16″ | 44215 | 415-116-15 | L4A-15 |
| 0.045″ – 1/16″ | 43215 | — | L4B-15 |
| 5/64″ | 44315 | 415-564-15 | L6A-15 |
| 3/32″ | 45415 | 415-332-15 | L7A-15 |
| 7/64″ | 45615 | 615-18-15 | L8A-15 |
| 1/8″ | 46715 | 615-18-15 | L8A-15 |
NOTE: Tregaskiss conventional liner numbers will continue to be offered due to their continued use in Tregaskiss robotic MIG guns.
B Series Small Curved Handle B Series Large Curved Handle O Series Small Curved Handle O Series Large Curved Handle T Series Small Straight Handle T Series Large Straight Handle C Series Straight Handle Please note that all handle and trigger combinations previously offered continue to be available within the BTB MIG gun platform. To view a summary of trigger options and other features by handle, please click here. .
Along with the new Bernard® semi-automatic MIG guns BTB platform launching on June 2, 2014, Bernard is pleased to announce the launch of the improved Q-Nut used on all Bernard rotatable necks. It has been completely redesigned to offer a significant increase in durability. Please note that the new silicone ring, Q-Nut cover and silicone insulator are now installed from the back of the neck instead of the front. “How to install the new Q-Nut” instructions are available on our website in the How-To Guides and Videos area of our Technical Support section. Please click here to access this How-To article.
Former Q-Gun™ and S-Gun™ MIG guns will require an additional character added to the end of the existing part numbers to allow for new liner selection options. Former T-Gun™ semi-automatic air-cooled MIG guns will be adopting Q-Gun style part numbering for consistency across all guns within the new single configurator. Example old and new part numbers are shown below: Q-Gun MIG Guns Q4015GE8CM Q4015GE8CMC S-Gun MIG Guns S3012TF5CM S3012TF5CMC T-Gun MIG Guns M3010-35 Q3010MP3CMC For a limited time from June 2 until August 1, 2014, both old and new part numbers will be supported in our system to allow our distribution partners to update their computer systems. To assist our customers in converting old gun part numbers to new Best of the Best Platform part numbers, we have created an online conversion tool. To populate the data in the tool, Q-Gun, S-Gun and T-Gun MIG Gun part numbers configured between April 2011 and April 2014 were pulled and converted to the new part numbering system. Click here to access this conversion tool.
Companies make the investment in welding automation with an eye toward the potential long-term benefits it can provide — better productivity, improved weld quality and reduced costs. Protecting that investment and realizing a quick return on it is as much a matter of planning as it is one of proper equipment selection and usage. That equipment includes everything from the largest components — the robot itself — to the smallest, including the front-end consumables on the robotic MIG gun. While seemingly insignificant, the nozzles, contact tips and gas diffusers used in robotic welding can have a marked effect on the overall performance of a robotic welding cell. Frequent changeovers can result in unnecessary downtime and costs. Poorly functioning consumables, or ones that are simply not appropriate for the application, can generate weld quality issues that compound productivity delays and could lead to expensive rework. Selecting the proper consumables and implementing some best practices for storage, installation and maintenance can help ensure the best results, increase product life and support the benefits sought in welding automation. Robotic welding systems typically operate for longer periods of time and at higher amperages than a semi-automatic application, and may utilize transfer modes that are especially harsh on consumables. For example, Pulsed MIG programs — those in which the power source “pulses” between low background currents and high peaks — tend to generate high levels of heat that can erode contact tips more quickly. For that reason, it’s important to select ones that are durable enough for the application. Contact tips are available in heavy and extended life heavy duty varieties composed of chrome zirconium, and are a good option for gaining longer performance due to their hardness (compared to copper). Typically, machined grooves at the base of the thread are the identifying mark for these types of contact tips. Selecting nozzles and contact tips that are well-machined with a smooth, consistent surface is key. Smooth surfaces are much less prone to collecting spatter, and therefore more likely to last longer. In some cases, these consumables may not be the least expensive option, but it’s important to weigh out the up-front costs versus the longer-term savings of minimizing changeovers and downtime. Space is always a consideration with robotic welding systems. Fixturing and tooling can limit the ability of the robot to maneuver to a part. Bottleneck, straight or tapered nozzles are common choices to accommodate for those restrictions since they are narrower than standard nozzles and can provide better access. The more tapered a nozzle, however, typically the thinner it is. As a result, it may be less able to withstand higher amperage or higher-duty-cycles commonly used in robotic welding applications. For jobs requiring 300 amps or greater and/or those that have a high level of arc-on time, it may be best to select a heavy-duty style nozzle. These have thicker walls and insulators and are more able to resist heat. In the end, a good rule of thumb is to select the heaviest duty consumable for the application that still allows access to the tooling in order to make it last the longest. If in doubt about the best choice, consult with a robotic integrator or welding distributor for a recommendation. Employing a nozzle cleaning station (also called a reamer) is a good defense against premature consumable failure and poor performance for many different styles of nozzles. A nozzle cleaning station cleans spatter out of the nozzle and clears away debris from the retaining head that tends to accumulate during the welding process. These stations can also be outfitted with a sprayer that applies a water-based anti-spatter compound to protect the nozzle, retaining head and workpiece from spatter after cleaning. For the best results, place the nozzle cleaning station close to the robot so it is easily accessible, and program the robot to use it in between cycles (during part loading or tool transfer, for example) so it doesn’t interrupt operation. It should only take 5-6 seconds for the nozzle cleaning station to complete its job and the results are measurable — less spatter and longer consumable life. As a best practice, keep consumables in their original packaging until they are ready for use. Opening them and placing them in a bin can lead to scratches or dents that allow spatter to adhere and will ultimately shorten the products’ life or cause them to function poorly. It can also cause dirt and oils to accumulate on the surfaces of the contact tip, which may impede them from properly seating together with the gas diffuser. It can also lead to electrical resistance and heat build-up issues that can, again, shorten their life span. Wear clean gloves when handling or replacing contact tips, nozzles and diffusers. It helps prevent dirt, oil or other contaminants from adhering to them and leading to premature failure or poor performance. ?Also, keep storage containers for new consumables separate from those for discarded ones to prevent the reuse of a contact tip or nozzle that may have dents or scratches and be prone to spatter accumulation. Good electrical conductivity helps ensure consistent arc performance and weld quality, and can help minimize excessive heat and extend the life of the consumables. Installing the consumables properly — according to the manufacturer’s suggestions — and periodically inspecting them for good connections is the best way to ensure that conductivity. Channel-lock pliers or other recommended installation tools work well to install contact tips and diffusers. Never use wire cutters or side cutters. Too much pressure from these tools can damage the inside diameter of the contact tip, and they can also cause scratches that attract spatter. A good rule of thumb is to hand-tighten the contact tip until it is fully seated into the diffuser. Next, grip the contact tip with an appropriate tool as close to the base as possible, tightening it one-quarter turn past finger tight. Follow the same procedure for installing and tightening the diffuser so that it fully connects with the neck. Some contact tips can be installed and held in place by hand-tightening the nozzle. Check the manufacturer’s recommendation for proper installation instructions. Finally, look for consumables that are designed to fully seat together and mate securely, too, as these can further increase their longevity by minimizing electrical resistance and heat build-up. As with any part of a robotic welding system, the goal is to keep consumables in the best working order so that the robot is able to continue doing its job. That, in turn, allows companies to spend more time reaping the benefits of the automated welding process and less time troubleshooting problems.
Consumables — contact tips, nozzles and gas diffusers (or retaining heads) — play an important role in the welding process and can impact productivity, costs and weld quality. Many factors influence the selection of consumables, including the application at hand, available budget and more. Some welding operations may view the purchase of consumables as a place to save money, since high-quality consumables typically cost more than lower-quality consumables. However, the up-front cost of consumables is just one part of the picture. Companies should consider the long-term benefits and savings that quality consumables can provide when making the selection, since consumables are an ongoing cost in the welding process. The optimal consumables are ones that provide the best quality and the longest life. These benefits in turn help lower replacement costs, minimize downtime and improve productivity. Also, quality consumables can often reduce post-weld cleanup work, saving time and money. The design, manufacturing process and materials are all characteristics that influence the performance of these components.
The Occupational Safety and Health Administration (OSHA) and other safety regulatory bodies set the allowable exposure limits for weld fumes and other particulates, including hexavalent chromium, with the aim of protecting employees against potential health hazards in the workplace. Providing welding operators with proper ventilation during the welding process is an important step companies can take to help meet the standards — and to help provide a safe and comfortable work environment. Companies may opt to invest in centralized fume extraction systems, which are designed to protect the entire shop area. These systems involve the installation of new ductwork and fans to remove fumes and are highly effective, but they are also more expensive than other options. A viable alternative for some companies is a fume extraction gun used in conjunction with a fume extraction device or localized filtration system. Fume extraction guns are available in a variety of amperages (typically 300 to 600), cable styles and handle designs. As with any welding equipment, they have their best applications, advantages and limitations, as well as recommended techniques for achieving the best results. Fume extraction guns operate by capturing the fume generated by the welding process right at the source, over and around the weld pool. The weld fumes removed by these guns are composed of a combination of the filler metal and base material. Various manufacturers have proprietary means of constructing guns to conduct this action, but at a basic level they all operate similarly: by mass flow, or the movement of material. A vacuum chamber suctions the fumes through the handle of the gun, into the gun’s hose and through to a port on the filtration system (sometimes informally referred to as a vacuum box). Typically, fume extraction guns are larger than regular welding guns, and include the vacuum and hose that are necessary to extract the fumes. Some manufacturers offer fume extraction guns with a vacuum hose swivel on the rear of the handle to make them easier to maneuver. Also, design advancements have minimized the handle weight and size to make the guns as light as possible for operator comfort, while still offering consistent fume extraction benefits. Fume extraction guns are especially well-suited for applications using solid welding wire and for those in confined spaces, where the goal is to capture fumes immediately at the source, in the welding operator’s breathing zone. Industries where these applications often occur include shipbuilding and heavy equipment manufacturing, as well as general manufacturing and fabrication applications utilizing mild or carbon steel. Petrochemical or other applications where stainless steel welding and greater hexavalent chromium levels are prominent may also present the opportunity to use a fume extraction gun. The guns work well on high amperage and high deposition rate applications. For the best results, fume extraction guns should be used for in-position welding, such as on flat butt welds. In this position, they can most effectively capture fume particles as they rise from the weld pool. It’s more difficult for a fume extraction gun to draw fume particles downward and through the vacuum hose in out-of-position welds, because the fume particles rise at a high rate in those cases. Techniques to maximize performance?The operation of fume extraction guns is similar to that of standard MIG guns, with many of the same recommended best practices. However, there are some techniques that welding operators can follow to help get the best performance from a fume extraction gun. Here are some things to remember: Perhaps the most important tip for maximizing performance is using the appropriate degree of angle. With solid wire — the most common filler metal used with fume extraction guns — use a push technique and an angle of 0 to 15 degrees, which is optimal for fume capture. For flux-cored wire (which generates more fume), use a drag technique with a 0 to 15-degree angle. If the parts are set up at a 0 to 30-degree angle and the gun is kept straight (vertical) during the welding process, the fume rises, allowing the fume extraction of the gun to be maximized. Travel speed during either of these welding processes will typically be dictated by the base metal and the wire size used. Because flux-cored wire produces a slag, it generates more weld fume. However, one benefit of using self-shielded flux-cored wire, for example, is it allows the ability to increase the vacuum level of the gun. Welding operators can close off all the vents and extend the shroud as far as possible. This action maximizes the vacuum at the front end of the gun without concern for disturbing the shielding gas, since there is none generates with self-shielded flux-cored wire. When using gas-shielded flux-cored wire, a 0 to 15-degree angle will help maximize fume collection. At the end of the weld, welding operators can pause for 10 to 15 seconds, holding the fume extraction gun in place without depositing weld metal. This action allows the gun to capture residual fumes as the weld bead is cooling. The contact tip to work distance can be longer — about 1/2 inch to 3/4 inch — when welding with flux-cored wire and a fume extraction gun. With solid wire, welding operators should try to keep the stickout to 1/2 inch or less to maximize fume capture. These lengths are comparable to the stickout lengths used with standard MIG guns. Some fume extraction guns feature adjustable extraction control regulators at the front of the gun handle, while other guns include this function internally. These regulators allow welding operators to increase suction as needed without affecting shielding gas coverage. The ability to balance between the downward flow of shielding gas and the upward flow of the suctioned air is important. Fume extraction guns need to provide the appropriate amount of shielding gas to protect the weld from defects such as porosity without sacrificing the ability to suction fumes efficiently enough to protect the welding operator. Adjusting the air control regulator to the appropriate level can be a matter of trial and error, so welding operators may want to test it on scrap material to optimize the suction rate before welding on a product. As with any piece of welding equipment, fume extraction guns benefit from preventive maintenance. Caring for them is similar to caring for a standard MIG gun. Also note that using flux-cored wire with these guns requires more frequent gun maintenance than solid wire because of the slag and fumes it generates. Regular maintenance is important to help prevent a clog or spatter buildup, which can limit the fume capture rate. Inspecting and maintaining the front end of the gun is key to optimizing fume extraction. Frequently inspect the nozzle and contact tip for signs of spatter buildup, which along with blocking the fume extraction can also obstruct shielding gas flow and cause weld defects. Spatter buildup also can cause consumables to fail prematurely. Replace the consumables if spatter buildup appears, or clean them according to the manufacturer’s recommendations. Also, inspect the vacuum hose regularly for damage such as cuts or kinks, which can lead to loss of suction. Replace a damaged vacuum hose as necessary. Regarding consumables, using the manufacturer’s recommended consumables package with a fume extraction gun helps optimize performance, as the guns are engineered to get the best results with specific consumables. When in doubt about maintenance or any other aspect of using a fume extraction gun, consider working with a trusted welding distributor, certified industrial hygienist and/or the gun manufacturer to address any questions or concerns. In combination with many other variables in the welding operation — wire selection, specific transfer methods and welding processes, welding operator technique, and base material selection — fume extraction guns can help companies maintain compliance with safety regulations and create a cleaner, more comfortable welding environment. Proper use and maintenance of the equipment is important to get optimal results.
We have added internal stops to all Centerfire™ and Quik Tip™ diffusers to improve alignment between the liner and contact tip for enhanced wire feedability. This product improvement is being implemented as a running change. The new internal stop inside Centerfire and Quik Tip diffusers prevents the liner from going all the way through the diffuser, therefore changing how liners need to be installed. Liner installation will now require the removal of the diffuser. Please note that trim lengths will also be affected. See product insert INS-DIFF for more information. How can I tell the difference between Centerfire and Quik Tip diffusers with the NEW internal stop vs. the original style Centerfire and Quik Tip diffusers? To help distinguish Centerfire diffusers (shown below, left) with the new internal stop, users can check the orientation of the roll mark. In original style diffusers, the roll mark is readable when the tip end is at the top. In diffusers with the new internal stop, the roll mark is readable when the neck end is at the top. To distinguish Quik Tip diffusers (shown above, right) with the new internal stop, users can check the roll mark. In the original style diffusers, the roll mark has one Bernard starburst stamped before the part number. In diffusers with the new internal stop, the roll mark has a Bernard starburst stamped before AND after the part number. For both Centerfire and Quik Tip diffusers, a second simple method to check for an internal stop would be to insert a liner into the diffuser. If the liner will not pass all the way through the diffuser, then an internal stop is present. Please note that it is important to understand which diffuser you are using as this affects liner trim length during replacement. Please refer to the insert inside of your diffuser bag or click here for additional information about liner replacement and trim length details.
June 1, 2013 Tregaskiss is pleased to announce improvements to the design of its cutter blades for use with the TOUGH GUN® TT3 reamer and TOUGH GARD® spatter cleaner robotic nozzle cleaning stations. These new cutter blades are engineered from harder, stronger material, making them more resistant to breaking, chipping or cracking. The twin flute design with stronger edges allows for improved cutting and cleaning performance. Click here to find out more about the features and benefits of these improvements. For use with the TOUGH GUN TT3 reamer: For use with the TOUGH GARD spatter cleaner: Binzel® is the registered trademark of Alexander Binzel Schweisstechnik GmbH & Co. KG, Germany. Panasonic® is the registered trademark of Panasonic Welding Systems Co., Ltd.
Companies invest in welding automation to increase productivity, improve quality and reduce costs. Any unnecessary downtime can quickly interfere with obtaining those goals. But what about small amounts of scheduled downtime for maintenance. In most cases, a well-planned, efficient preventive maintenance (PM) program can yield positive results. Not only does it help ensure reliable throughput, but a properly executed PM program can also lower labor costs, reduce waste and minimize rework. It may even expedite the return on investment (ROI) in the automated welding system. Caring properly for the whole of an automated welding system is imperative, of course, but so too is maintaining the robotic MIG gun. In fact, the robotic MIG gun and its consumables are frequently overlooked components in the system. They are also relatively easy to maintain, and doing so can positively contribute to the efficiency of the entire welding operation. All companies, regardless of their size or arc count, can benefit from regular maintenance of their robotic MIG guns and consumables. The scope of the PM program, however, will vary according to each company’s application. For example, a company with higher-risk applications — those with large, thick parts; long cycle times and/or expensive rework — generally require more frequent care of the equipment than companies that weld smaller, less expensive parts. They simply stand to lose more (in both downtime and money) should something go wrong in the welding process. Most of the maintenance on a robotic MIG gun can be completed shift-by-shift with minimal off-line time. Welding engineers, welding supervisors, tool and die employees or members of the maintenance staff are all viable candidates to oversee the process. All personnel involved, however, need to be properly trained to identify potential problems in the weld cell and learn how to prevent them. They should also be aware that “in-process” maintenance does not constitute the whole of a PM program. Some activities may need to take place off-shift due to their complexity and the time needed to complete them. There are several key components to a good PM program for robotic MIG guns. Before starting any task, it is important to have the correct tools for the job. For example, be sure to have the proper adjustable or crescent wrench for changing diffusers or retaining heads, as well as the recommended pliers, welpers or tip installation tools for installing contact tips. Keep a sharp pair of side cutters on hand, too, to trim the robotic MIG gun liner. These tools help prevent burrs on the liner that can wear or drag on the welding wire. After establishing that the proper tools are in place to support the PM program, consider the following practices. During pauses in production — when the robot finishes welding a part or during routine contact tip changeover, for example — check for clean, secure connections between the MIG gun neck, the diffuser or retaining heads and the contact tip. Also, check that the nozzle is secure and any seals around it are in good condition. Having tight connections from the neck through the contact tip helps ensure a solid electrical flow throughout the components and minimizes heat build-up that could cause premature failure, poor arc stability, quality issues and/or rework. It also reduces the opportunity for burnbacks, which can lead to unplanned downtime for changeover. Look for changes in consumable colors, too, as those are a good indication that they are loose and require tightening. Spatter build-up can cause excessive heat in the consumables and MIG guns, block shielding gas flow, and increase costs for inventory and downtime to change over nozzles, diffusers and contact tips. Visually inspect consumables on a regular basis for signs of spatter, replacing them as needed. Also, consider adding a nozzle cleaning station (also called a reamer or spatter cleaner) to the weld cell. Like its name implies, a nozzle cleaning station removes spatter (and other debris) that builds up in the nozzle and diffuser. Using this equipment in conjunction with a sprayer that applies an anti-spatter compound can further protect against spatter accumulation. Track how long it takes for the liner in the robotic MIG gun to become worn or fouled, and schedule a replacement as needed. Replacing the liner prior to a failure prevents unplanned downtime to remedy wire feeding or quality problems later. Also, always cut the liner according to the manufacturer’s recommendation to prevent kinking and poor wire feeding that can lead to premature contact tip failure and/or arc instability. Periodically, release the drive rolls and check the force required to pull the welding wire from the feeder through the robotic MIG gun. Excessive drag indicates that there is a build-up of debris in the liner and it needs to be replaced. It is best to perform this task in between shifts, as opposed to during contact tip changeover, as it tends to take more time. Check regularly that the welding cable leads are properly secured and assess the condition of the welding cable on the robotic MIG gun. Look for signs of wear and be certain that the cable is not rubbing against any part of the robot’s metal casting, as that friction can cause the cable to loosen or become damaged. A worn spot on the robot (e.g., the absence of paint) or on the tooling is a good indication that the cable is rubbing against it. Rectifying the situation will likely involve repositioning the tooling or a cable management device and may need to occur while the robot is off-line. Still, a quick in-process inspection that identifies the issue can flag it for a later, proactive solution. Preventive maintenance programs don’t have to be complicated — only effective. Most of the robotic MIG gun maintenance discussed here can be completed on a shift-by-shift basis with minimal interference to cycle times and with minimal labor costs. The scope and frequency of a PM program will vary from company to company, of course, but carefully executed maintenance activities can help companies better realize the potential of their automated welding operation. And it can reduce costs by preventing problems, instead of being forced to resolve them.
Worldwide, companies serving the automotive industry have faced a unique set of challenges in the last several years, including changes in material types, a lack of skilled labor and initiatives by OEMs to decrease the weight of vehicles. Still, as the economy continues to rebound, each must find ways to maintain their productivity and profitability — often with fewer employees than before the recent recession. A large part of maintaining that productivity is to ensure high levels of uptime in the robotic welding operations in order to maximize net throughput. It is equally important to find ways to minimize errors and obtain predictive weld data to help anticipate problems in the operation. Conventional issues like spatter, burn-through and poor part fit-up often hinder these attempts, as can the need to manage large amounts of inventory and contend with downtime to service welding equipment. That’s why it’s so important, too, for companies to find equipment that minimizes the total cost of ownership. Unfortunately, there is no single answer to these challenges. There are, however, some considerations that may help reduce automotive suppliers’ pains and assist in other interrelated parts of the process. Best practice meetings: When possible, suppliers in the automotive industry should work with original equipment manufacturers (OEMs) and vendors or welding distributors who can engage regularly in best practice meetings. These meetings can occur by conference call, webinar or in person, and can help determine what practices in the welding operation are working most effectively and what areas need improvement. “Open issues” can be prioritized in order to determine time-phased solutions. These meetings can be especially helpful to companies with multiple locations (even globally), since they help identify opportunities for changes that could positively affect other facilities. They are also an excellent platform for brainstorming error-proofing ideas and serve to open communication among the parties involved in the success of a company’s welding operation. Ultimately, the goal is to spread an assessment of the operation to a broader peer group, extending the company’s core competencies to gain solutions from others’ input. Streamline vendors: Automotive suppliers, particularly those with multiple locations, may want to consider purchasing their robotic gas metal arc welding (GMAW) guns, peripherals, consumables and other welding supplies from a single-source vendor via a welding distributor. Having multiple vendors may appear to provide cost savings on the surface; however, a per-item approach can actually increase the total spend. Instead, by single sourcing a product line, a company is better poised to maximize their purchasing power with one vendor and gain loyalty discounts. The vendor may also be more inclined to aid in new efficiencies and groundbreaking technologies. Plus, a trusted single-source vendor can often help automotive suppliers assess their total weld spend, streamline inventory and reduce costly paperwork. The goal is to work with a vendor who can “own the arc,” providing assistance throughout the whole welding operation by assessing predictive data and offering suggestions for ongoing improvements. “Co-opetition”: If you already work with several welding vendors, co-opetition is your next best option to maintaining an effective welding operation and in some cases can occur as part of best practice meetings. This term refers, in short, to cooperation that occurs between the various equipment manufacturers who are building the end user’s welding solution. Sometimes these companies have competitive product overlap. For example, the manufacturer of the robotic GMAW gun or welding wire may be in direct competition with the company whose power sources are in an automotive supplier’s weld cell. Even so, finding equipment manufacturers who are willing to work together to address problems in the welding operation is key to resolving issues when they arise. A problem with the contact tip, for example, is usually a barometer of other things happening in the process. In short, it is very often a symptom of a problem, as opposed to the root cause. Having partners who are willing to put aside competitive differences for the good of resolving problems like these is important to gaining good welding performance. If this co-opetition is not feasible, companies may want to consider moving to a single-source vendor. Equipment standardization: Recent increases in demand for production have caused some automotive suppliers, especially those in North America, to make capital investments that they previously postponed during the recession. When possible, standardizing on a single brand and style of welding power source, robotic controller, and GMAW gun and consumables during this investment can streamline inventory and maintenance procedures, thereby lowering management costs. It can also help companies avoid long lead times associated with specialty products and improve access to spare parts. For companies in an organic growth mode with new programs and/or greenfield operations, this standardization can help in long-term equipment re-deployment to other facilities, as well as streamline the learning curve among employees, and improve adoption rates and costs. For companies that are in acquisition mode, however, this standardization may not be feasible. Instead, these suppliers should, at a minimum, consider standardizing on a single brand and style of robotic GMAW guns and consumables to minimize inventory. Doing so can also reduce the risk of improper consumable installation, which often leads to unscheduled downtime to rectify. Appropriate welding technology: Many automotive suppliers rely on tandem- welding operations as a means to generate greater productivity. Companies can use this process for line production in the cells housing the majority of the welds. The benefit is that these operations require less floor space and can simultaneously improve throughput. Advancements in single arc pulsed technology have also proven very efficient in providing faster travel speeds and minimizing spatter. This single arc technology, which effectively lowers the average amperage level during welding (by regularly switching the current between high peak amperages and low background amperages), is also quite easy to operate. Given the reduction in workforce in the automotive industry, combined with an overall shortage of skilled labor, this less complex (but highly efficient) technology has already proven beneficial for many automotive suppliers. Companies should work with an appropriate welding distributor or robotic integrator to assess the individual application in order to determine the most appropriate welding technology. Error-proofing: In addition to standardizing equipment when possible, using welding products that minimize the opportunity for human errors is an important part of keeping the welding process flowing. For example, nozzle detection can eliminate the potential of excessive rework or scrap. Avoiding errors in equipment installation is also critical, as missing or incorrectly installed components on the front end of a robotic GMAW gun can cause it to become electrically alive, leading to premature failure and poor welding performance. Preventive maintenance: Even though preventive maintenance or PM may have become a commonplace buzzword in recent years, the fundamentals are still critical to providing good welding performance and reducing unscheduled downtime in the automotive industry. Companies should take care to inspect all connections in the ground cables, feeding assembly, wire feeder, GMAW gun and consumables on a regularly scheduled basis. Replacing worn components during scheduled downtime (at the beginning of a shift, for example) can help prevent problems during production. On some welding robots, “predictive maintenance” technology is available to send alerts when consumables need to be changed. Built-in buffers: As is typical in automotive “just-in-time” applications, suppliers want to reduce work in progress (WIP) — maintaining only strategically determined micro-inventories — and keep parts flowing (Takt time). To continue that workflow but still allow for any instances of stoppage in a robotic welding cell, suppliers may consider building a buffer into production. For example, if a company has a production line of 40 welding robots, breaking that line into fifths (five sections of eight robots), allows them to address any instances of failure while causing a stoppage of only eight robots instead of shutting down production on all 40. That buffer can mean a significant difference in terms of lost production and money. And while no single one of these considerations can ensure the levels of productivity and profitability to which automotive suppliers strive as production demands increase, they can be a step in the right direction. Automotive suppliers should consider working with a trusted welding equipment manufacturer and vendor to discuss a plan for assessing their robotic welding operation and identifying opportunities for improvement.
Consistent productivity, high quality and low costs are all key components in a successful welding operation. Gaining these advantages depends on everything from the equipment and filler metals to the skill of the welding operators and the techniques being used in the process. The shielding gas also plays a critical role. Both the gas metal arc welding (GMAW) process (using solid or metal-cored wires) and the gas-shielded flux-cored arc welding (FCAW) process require the use of an external shielding gas, each type of which offers distinct characteristics. Knowing how to select the appropriate one for the application can go far in helping obtain the desired welding performance and minimizing the downtime for rework caused by poor weld quality. To help, following are some basics of what you should know about shielding gases. The primary purpose of shielding gas is to protect the molten weld pool against elements in the atmosphere, including oxygen, nitrogen and hydrogen. The reaction of these elements with the weld pool can create a host of problems, including (but not limited to) porosity and excessive spatter. Shielding gas also plays an important role in determining weld penetration profiles, helping maintain arc stability and achieving the desired mechanical properties in the finished weld. Shielding gas can also affect the transfer of the filler metal from the arc to the weld joint, which in turns contributes to the efficiency of the welding process and the quality of the weld. Other important factors that shielding gas help determine include the weld bead appearance, and weld toughness and strength. The four most common shielding gases used in the welding process are carbon dioxide, argon, helium and oxygen. Each has specific characteristics and factors such as cost, available labor (i.e., for weld preparation) and the weld properties desired — all considerations when selecting which shielding gas is best for a given welding application. Carbon dioxide (CO2): This gas is the most common of the reactive gases used in the welding process and also the least expensive of the shielding gases. It is also the only one able to be used without the addition of an inert gas. One of the biggest advantages of pure CO2 is that it provides deep weld penetration, which is useful when welding thick material. It does, however, tend to create a less stable arc and more spatter than when it is mixed with other gases, including argon. This additional spatter can lead to downtime for post-weld cleaning. Pure CO2 is also limited to use in short circuit welding processes. Argon: When welding aluminum, magnesium or titanium, it is common to use 100 percent argon as a shielding gas due to its stable arc features. Adding argon to a CO2 shielding gas is also an option for materials like carbon steel. It provides consistent weld quality and appearance and good weld pool control, and can help minimize post-weld cleanup. Argon also produces a narrow penetration profile, making it useful for fillet and butt welds. Typical mixtures include a balance of 75 to 95 percent argon with 25 to 5 percent CO2. An argon/CO2 shielding gas mixture allows the use of a spray transfer process, which lends itself to high productivity rates and visually appealing welds. Helium: Helium is generally used when welding non-ferrous metals. It is also used in a tri-mix formula of argon and CO2 for welding stainless steels. The gas produces a wide, deep penetration profile, making it suitable for welding thick materials, and also creates a hot arc, which helps increase travel speeds and productivity rates. Helium is typically used in ratios of 25 to 75 percent helium with an appropriate balance of argon. Adjusting these ratios changes the weld penetration, bead profile and travel speeds. It’s important to note that helium is more expensive than other gases and requires a higher flow rate than argon (because it is so light). For this reason, it’s imperative that companies calculate the value of the productivity increase against the increased cost of this gas. Oxygen: Oxygen is a reactive gas typically used in ratios of 9 percent or less. The addition of the gas to a mixture with argon helps to improve weld pool fluidity, weld penetration and arc stability, particularly when welding carbon, low alloy and stainless steels. Because the gas causes oxidation of the weld metal, it is not recommended for use with aluminum, magnesium, copper or other exotic metals. To achieve the best results out of a chosen shielding gas, it’s important to select the proper front-end consumables. These consumables — the gas diffuser, contact tip and nozzle — play a critical role in delivering the shielding gas to the weld pool and also protecting it from the atmosphere. Consider these tips to help with the selection. 1. Choose consumables that have a smooth surface to help resist spatter build-up that could block shielding gas flow and lead to issues, such as porosity. 2. Choose an appropriate size nozzle for the application. A nozzle that is too narrow for the application can easily become clogged with spatter, again, hindering its ability to deliver enough shielding gas to the weld pool to protect it. 3. Consider using nozzles with a built-in spatter guard. These designs add a second phase of shielding gas diffusion, resulting in even smoother, more consistent shielding gas flow. 4. Be certain to select quality gas diffusers to ensure smooth and balanced gas flow. Consult with a trusted welding distributor for recommendations. When your company is responsible for rebuilding, repairing and up-fitting vehicles that deploy to firefighting and rescue situations day in and day out, quality is non-negotiable. Every component must be precisely tooled, every weld precisely placed. The employees at True North Emergency Equipment can certainly attest to that fact. They are a premier service provider for custom fire engines, water tenders, and rescue and emergency vehicles used across the United States, and especially in the Northwest. “Our people understand and believe that our vehicles need to be serviced to complete their mission. They are lifesaving vehicles,” explains Russ Sheldon, operations manager at True North Emergency Equipment. “We don’t just inspect quality into our products. It has to be built in there.” That philosophy spans every aspect of the Hillsboro, Ore.-based company. According to Sheldon, almost every vehicle the company works on is unique, which means it requires the right equipment to work on it – regardless if the job is rebuilt, repaired or upfitted. Recently, True North Emergency Equipment added new MIG welding guns and consumables from Bernard to their welding operation. They found that the products didn’t just stand up to the tough demands of their applications, but that the MIG guns also proved more versatile and comfortable for the welding operators. Plus, the consumables helped reduce their inventory and costs. Not surprisingly, these are benefits that the fabricators and management alike welcomed. In a typical day at True North Emergency Equipment, there are no typical applications. The company could be welding 1/8-inch-thick sheet metal compartments or working on 1/2-inch steel mounting brackets. Most days, fabricators also tackle the nuances of aluminum welding for good measure. Adding to the challenge of welding multiple materials, these same fabricators also find themselves working at awkward angles on a regular basis. According to Sheldon, “Fabricators here weld overhead, vertical and horizontal, and a lot of the components we fixture. So to say we have a standard welding position or a set position … no, that would not be the norm here.” Despite those challenges, the welds have to look, in Sheldon’s words, “sharp.” “Anything exposed has to look top notch. The care in the detail basically has our fabricators’ artistic signature on it,” he adds. Kyle Plock, a True North Emergency Equipment fabricator, has noticed that the company’s new Bernard Q-Gun™ (400 amp) series MIG guns help make that quality easier to achieve — even on out-of-position welds. The gun features a rotatable neck that users can change the position of without any tools. They simply unscrew the durable plastic ring at the base of the neck, rotate the neck to the desired angle and tighten the ring. “With the Q-Gun MIG gun, all you have to do is loosen the neck, turn it and tighten it back up where you want it,” says Plock. “With the old guns, we had to get an Allen wrench, loosen the socket head cap screws, then turn the neck and tighten it back up. So this [gun] is a lot quicker and easier.” Plock adds that this feature comes in handy especially when he’s working on an application that doesn’t allow him a lot of room to maneuver or reach for tools (as would be needed to change neck angles on the older style guns True North Emergency Equipment used). “If we’re inside of a truck in the pump house welding a structure, I often have to turn from one direction to another,” he explains. “If I want this neck to go a different way to fit in a tighter spot, I can turn it without having to twist my hands around.” The addition of a dual schedule switch on the Bernard Q-Gun series MIG guns that the company uses adds to its versatility for fabricators like Plock and the other fabricators. The dual schedule switch allows them to change wire feed settings (without having to go back to the power source) when they alternate between welding thinner and thicker materials. “Personally, I like that if I’m at the top of a truck and need to make an adjustment [to the wire feed speed], I don’t have to climb all the way down to the machine, make the adjustment and then climb all the way back to where we were working,” says Plock. “With this setup here, we don’t have to do that. I just make my adjustment and keep on going. It’s a lot more efficient.” Mitch James, plant manager and field trainer for True North Emergency Equipment agrees that these features and the versatility that his team gets from the new MIG guns is an asset. “The features have made a big difference in comfort and in improving throughput time. There’s just no messing around and adjustment with them,” James explains. True North Emergency Equipment paired its new Bernard Q-Gun series MIG guns with the Centerfire™ consumables system, also from Bernard. These consumables feature a “drop-in,” threadless contact tip that fabricators can change back quickly after a burnback to help reduce downtime and get them back to work faster. The contact tips also have a large diameter tip base and tapered seat that, combined with the gas diffuser, provides better electrical conductivity and heat transfer. For True North Emergency Equipment, those features translate to one single benefit: The consumables last longer than their previous brand. “There was a time when we would have to buy our welding tips 25 or 50 in a bag,” says James. “I actually had team members come to me [before Centerfire] and say they were running through three, four, five, six, eight tips in a matter of just a few hours from burnbacks and such things.” Since the conversion to the Centerfire consumables system, James says that their consumable usage has dropped tremendously. “We don’t have to stock nearly as much anymore. We’re stocking about 75 percent less or about 25 percent of what we used to stock in consumables,” he explains. “That’s saving us quite a bit of money.” It’s all about quality at True North Emergency Equipment — and quality is what keeps the company’s customers and employees happy. The fabricators and management all take pride in knowing that they are helping rebuild, repair and refurbish the best, safest and most durable fire and rescue vehicles for their customers. “Every customer has exacting spec and we suit that need. That’s our niche. That’s who we are,” says Sheldon. “And cater to the high end of the market — always.” That the company has found the right tools to help its employees reach that goal isn’t lost on them, says James. “In the end, it’s all about attitude; emotions; how people feel about what they’re doing. If you feel good, you’re going to do good. So that’s the whole ball of wax right there.”
The improved swivel design on the Bernard® FILTAIR™ fume extraction MIG gun now uses threads to retain the vacuum hose and eliminates the front band-it clamp from both amperage models. This redesign will improve performance and avoids replacing the hose clamp with a larger head. The new design threads into the vacuum hose and cannot be removed unless the hose is cut to remove it from the threads. Removing the front band-it clamp also eliminates the possibility of the clamp getting snagged on other equipment, gloves, clothing, etc. Did any part numbers change? Answer: The new threaded swivels are backwards compatible with existing guns. As a result, swivel part numbers did not change. How can you tell the difference between the old version and the new 2013 design? Answer: New 2013 design will not have the metal front band-it clamp located on the hose near the rear of the handle. See Figure below:
March 1, 2013 Tregaskiss is pleased to announce an improvement to our fixed automatic series MIG guns. These robust machine torches are engineered for hard tooling applications requiring a durable welding torch, and they now feature a one-piece high strength phenolic handle.
Your welding operation, just like any other portion of your business, offers opportunities to conserve resources. Consider these 10 money-saving tips for MIG gun care and maintenance as a good first step. And don’t be surprised when you find these tips improve your welding performance along the way! Keep your nozzles, gas diffusers and contact tips in the original package in which they were shipped until you are ready to use them. Doing so prevents scratches and/or dents where spatter can accumulate and cause the consumables to fail prematurely. It also prevents dirt, oil or other debris from adhering to the consumables and inadvertently entering the weld puddle. Remember, proper storage and handling doesn’t just lower your actual costs for consumables, it can also prevent weld defects that require costly rework. Choose the most appropriate neck for your MIG welding application in order to increase comfort and control, and save money. Rotatable necks, for example, adjust without tools so that you can quickly change neck angles by loosening a plastic ring and tightening it once you’ve determined your desired position. These types of necks are especially useful if you find yourself welding on many different applications and angles throughout the day, and they minimize costs for inventory and changeover. For hard-to-reach areas, you may also want to consider a neck coupler, which allows you to connect two existing necks together to extend your reach — again without the cost of purchasing a new or specialized neck. Flex necks are also a good option for saving money, and gaining greater comfort and control, particularly for applications with tighter joints. You can bend these necks to multiple angles to work around corners or get into small spaces without the expense of stocking different neck angles. Regularly perform a visual inspection of your nozzle — inside and outside — to look for spatter build-up. If there is accumulation, either clean the nozzle with a tool designed specifically for the job or replace the nozzle if necessary. During your inspection, also check that the nozzle, contact tip and retaining head are tightened properly, as these components can naturally loosen during welding. Inspecting and tightening your consumables regularly (several times during a welding shift is ideal) help ensure good shielding gas coverage, reliable electrical conductivity and consistent weld quality. Always trim your MIG gun liner according to the manufacturer’s recommendations, using the proper tools and cutting it to the correct length. Too long of a liner can cause kinking, while cutting it too short allows debris to build up between the liner and the gas diffuser. Either way, the wrong liner length can cause poor wire feeding and premature failure of both the liner and the contact tip. When possible, use a liner gauge to determine the proper length for your particular liner and be certain that there are no burrs or sharp edges after you cut it. Also, keep the liner away from contaminants (e.g., don’t let it drag on the floor) during installation and be sure your hands or gloves are clean. These precautions help prevent contaminants from entering the weld puddle and causing costly weld quality issues. Consider using a front-loading MIG gun liner to ease and speed liner replacement. This type of liner cuts installation time nearly in half compared to using a rear-loading liner, saving you downtime and unnecessary labor costs for changeover. Some manufacturers offer a spring-loaded module that works in conjunction with a front-load liner to help minimize issues if you accidentally trim the liner to an incorrect length. These modules are housed in the power pin and put forward pressure on the liner after installing it from the front of the gun. The modules allow up to 1 inch of forgiveness if the liner is too short. There are also jump liners available. These replace only the most commonly worn and clogged liner area — from the neck to the contact tip — to reduce the amount of time a gun is offline and minimize inventory for full-length liners. These jump liners enable quick and easy neck change-out so the MIG gun can be easily adapted to fit multiple applications. When appropriate, switching from heavy-duty contact tips to standard-duty ones can help lower your overall consumable costs, while still providing you with reliable welding performance. If you have lower heat applications, brief arc-on times for short welds or tacks, or if you are using mixed shielding gases and small diameter wires, standard-duty contact tips may be a better option and they cost less. You can also use these types of contact tips if you have applications with restricted access, as the smaller outside diameter can help increase gas coverage and reduce the nozzle’s bore size, making it easier to reach tough joints. Look for non-threaded contact tips that connect or seat securely with the gas diffuser. This type of design provides consistent electrical conductivity and helps dissipate heat more readily. That’s important, since cooler running consumables last longer and provide more consistent performance. A nozzle with a thread-on design helps keep the contact tip centered for better weld placement and it can minimize the opportunity for spatter. This type of design can also withstand demanding jobsite use and abuse. As an additional defense against spatter accumulation, purchase nozzles that have a smooth, non-porous surface. Be sure that the nozzles are free of any sharp edges or flat spots that would further allow spatter to adhere. As when handling the liner, be sure you have clean hands or gloves when you are handling or installing your nozzle. Dirt, oil, grease or other debris can easily adhere to nozzles and later enter the weld puddle, causing weld defects. These contaminants can also cause premature failure of the component. Use the shortest length MIG gun cable possible for your welding application, as it helps prevent kinking and premature wear of both the cable and the MIG gun liner. It also helps prevent wire-feeding problems that could lead to an erratic arc, poor weld quality and unnecessary downtime for rework or consumable replacement. Steel monocoil cables are also an excellent means to prevent kinking. Also, remember to choose the correct diameter liner and contact tip for your welding wire, as this prevents similar problems and helps extend the life of these consumables. Whenever possible, purchase MIG guns and consumables that are backed by a reliable manufacturer’s warranty, and use all guns and consumables as intended so as not to void the terms and conditions. Also, consider the up-front cost versus the long-term savings of purchasing sturdier and more expensive consumables. They will likely last longer, reducing downtime associated with changeover and the cost of the consumables themselves. Keep these tips in mind and you can get back to welding faster… and keep conserving your resources.
Implementing a robotic welding system isn’t something that happens on a whim — at least not successfully. Converting to this technology can help companies gain greater productivity, improve quality and reduce costs in the welding operation, but the process requires thorough planning to gain those results. Working closely with a robotic integrator is a good step to ensure every aspect of the implementation is carefully orchestrated and that the robotic welding system works properly for the given application — in reality, not just theory. Before adding a robotic welding system, it’s helpful to know some key factors that can maximize the return on investment (ROI) in the technology and also help prevent potential problems. The quality of part produced by a robotic welding system depends on the quality of the part that enters the weld cell. That’s why it’s not uncommon to hear the phrase “garbage in, garbage out” when it comes to robotic welding systems — if the part entering the welding cell is flawed, the subsequent weld will be, too. To protect against poor weld quality, it is critical to have simple, consistent parts that allow the robot to execute the weld in the same location, repeatedly. Having a blueprint or electronic CAD drawing is helpful for confirming that repeatability. Robotic integrators can review the blueprint or they may want to create a software simulation that assesses the suitability of the part for the robotic welding system. After the assessment, they can advise of any adjustments that need to be made prior to implementation. Proper fixturing is also critical to achieving part repeatability, regardless of whether the application is high volume/low variety or low volume/high variety. Parts that meet the exact specifications can easily be welded incorrectly if they are not held in an exact position during the process. Many robot manufacturers offer vision systems to aid in part recognition and to ensure that the weld path can be altered in real time if part fit-up issues exist. These systems usually work very well, but may cost more. Robotic welding systems require a properly trained operator to oversee them. A skilled welding operator or an individual with previous robotic welding management experience is a good candidate for the job. Again, a trusted robotic integrator is an excellent resource to provide the necessary training, which should cover proper programming, troubleshooting and preventive maintenance. As a best practice, companies should also consider ongoing training support to keep the operator’s knowledge of the system up to date. In many cases, robotic OEMs offer online tutorials, troubleshooting information and/or additional on-site training as aftercare support. Many facilities already have fume extraction systems in place for manual welding operations, but converting to a robotic welding system may require additional equipment to help maintain a healthy work environment. With the increased production brought forth by a robotic welding system, there is also an increase in fume generation. Given the stringent regulations and recommendations from OSHA (Occupational Safety and Health Administration) and other safety regulatory bodies, proper equipment is necessary to maintain compliance. For larger facilities with higher production robotic welding applications, a centralized fume extraction system is a good option. These systems involve the installation of ductwork throughout the facility and the placement of fume extraction hoods over the welding cell. Smaller shops with fewer robotic welding cells may want to consider a less expensive portable fume extraction system. Operators can wheel these systems right next to the welding cell and adjust the extendable arm toward the robot to suction the fumes. It is also critical that the proper cage and screens are in place around the robotic welding system to protect employees from the welding arc and moving parts within the cell. Adding weld data monitoring capabilities and/or peripherals into a robotic welding system can help improve weld quality and productivity. Achieving these results, however, requires an additional up-front investment. Weld data monitoring (whether integrated in a power source or via a third party) allows companies to track the parameters of individual welds, determine the cause of weld defects and identify general inefficiencies in order to rectify those problems and optimize the process for peak quality and productivity. This equipment requires the purchase of software and computers, as well as the establishment and maintenance of an Ethernet network throughout the facility. Companies will also need tech-savvy individuals to review the data and make the necessary adjustments to the robotic welding system according to the data provided. Similarly, the addition of peripherals — particularly a nozzle cleaning station (also called a reamer or spatter cleaner) can improve weld quality and productivity. By cleaning spatter from the inside of the welding consumables on the front end of the GMAW welding gun, this peripheral helps extend consumable life, reduces downtime for changeover during production and also reduces the cost for replacing consumables. Nozzle cleaning stations also help minimize the loss of shielding gas coverage (due to spatter build-up) that could lead to poor weld quality and rework. Preventive maintenance of the entire robotic welding system, including the robotic GMAW (gas metal arc welding) gun, consumables and cables is an important step in protecting the investment in this technology. Neglecting maintenance can easily lead to unscheduled downtime, poor quality parts and/or costly repairs. It may even lead to failures that require equipment replacements. Scheduling time to check connections throughout the system, clean fixturing (to prevent debris that may affect part fit-up) and check TCP (tool center point) helps ensure that the robotic welding system continues to operate within its proper parameters. Certain maintenance can occur in between shifts — cleaning off the robot or changing consumables, for example — while other activities like greasing the robot’s joints may occur less frequently and during a longer scheduled stop. Companies need to assess their individual needs and plan the preventive maintenance schedule accordingly. For larger companies, hiring a maintenance crew to take care of preventive maintenance may be desirable. Retrofitting robotic welding systems is a common practice among many companies, particularly those investing in automation for the first time or for smaller shops requiring only one or two weld cells. It’s significantly less expensive to purchase a used robot than a new one. When retrofitting a robot, however, it is absolutely essential that it is capable of communicating with the selected power source if companies are to have the entire robotic welding system function properly. New power sources feature software that may not be immediately compatible with a robot that is older, or in some cases, the robot may need a specific robotic GMAW gun that isn’t readily available at a welding distributor or possibly even discontinued. For this reason, it is critical to contact an experienced robotic integrator who can both recommend and help set up all components in the retrofitted robotic welding system. The investment in this assistance can help ensure the proper functioning of the equipment and the long-term cost savings sought by implementing the system. Not to mention, it can also save a lot of frustration and downtime. Robots rely on the input of the operator to execute a given task. That task, however, doesn’t have to be limited to just welding or to welding the same part every time. Operators can program the robot to weld multiple parts over the course of a single shift, enhancing the versatility of the robotic welding system and positioning the company to produce additional output. Operators can also program robots to move parts so that a particular unit is not sitting idle when it isn’t tasked with welding; there are components that offer gripping capabilities and can be installed in addition to a welding gun. Companies may even have a tool dock that allows the robot to be fitted with a different tool and proceed with its work. Some companies with multiple robots may also benefit from installing a vision system in order to check on the work of the others, ensuring that part fit-up is optimal and that the robot is correctly placing welds. Given that the goal of any robotic welding system is uptime, having the versatility to use a robot for multiple tasks can contribute meaningfully to the other advantages of this technology – increased productivity, improved quality, decreased costs — and may help give companies a real competitive edge.
Investing in welding automation can be a relatively quick way for companies to achieve greater productivity, improve weld quality and reduce costs. But protecting that investment is key to maintaining these benefits over the long term. Preventive maintenance (PM) programs are an easy and cost-effective way to help. These programs not only protect against costly downtime, but they can also help lower labor costs, reduce waste and minimize rework. In some cases, they may even expedite the return on investment (ROI) in the automated welding system. PM programs, however, shouldn’t be limited to just the robot or the power source. Protecting your robotic MIG gun and consumables with a PM program is also critical. It can help minimize weld defects, reduce downtime for changeover, and keep the robot up and running longer. Consider these tips to help along the way. There are four key tasks to consider as part of the PM program for your robotic MIG gun and consumables. During routine pauses in production, look for secure connections along the length of the robotic MIG gun. Be certain that the MIG gun neck, retaining head (diffuser), contact tip and nozzle are all tight and clean. Also check that the seals around the nozzle are in good condition. Good connections help ensure smooth electrical flow and minimize heat build-up that could lead to poor welding performance and/or premature consumable failure. Look for signs of wear on the welding cable and make sure that you have properly secured welding cable leads. Also, make sure that the welding cable isn’t rubbing against any part of the robot’s metal casting, as friction can cause the cable to loosen or become damaged. Inspect the power pin, as well, to make sure it is secure. Regularly inspect the nozzle, contact tip and retaining head for spatter build-up and replace these consumables as necessary. Spatter build-up can block shielding gas flow, leading to poor weld quality, and also lead to premature consumable failure due to a build-up of heat. Ideally, use a nozzle cleaning station (also called a reamer or spatter cleaner) in conjunction with a sprayer that applies anti-spatter compound to minimize spatter build-up. Track how long it takes for the liner in your robotic MIG gun to become worn and schedule a replacement accordingly. Gauging the life of your liner can help prevent unplanned downtime to address wire-feeding or quality issues resulting from routine wear or clogging. For all preventive maintenance on your robotic MIG gun, be sure to use the proper tools for the job. Robotic MIG gun and consumable manufacturers typically provide recommendations for their products. The frequency and scope of PM activities for your robotic MIG gun depend largely on your application. You should be able to complete most activities, such as checking for secure connections or consumable changeover, on a shift-by-shift basis during routine pauses in welding. Other activities, such as liner replacement, may take longer and need to be completed off-shift. Regardless of whether you weld a high-volume components or larger low-volume assemblies, you should manage the period of time in between routine robotic MIG gun inspections to effectively reduce the downtime required to complete the PM cycle. A small investment of planned down time will mitigate the risk of larger challenges that most often prove more costly in terms of time. For all types of applications, it’s best to develop an initial plan for PM activities for your robotic MIG gun. Once developed, you can adjust accordingly until you feel that you have the program that works best for you.
Jolson Welding deals in heavy steel. The company specializes in structural welding for bridge and highway work in one of the most seismically sensitive areas in the world: Northern California. Working with the state department of transportation and local contractors, Bob Jolson (owner, operator, welder) and his team have established welding processes that meet strict code requirements (CalTrans, AWS D1.8 and D1.5), and pass ultrasonic and x-ray tests without fail. A recent job welding soldier pile highlighted the soup-to-nuts mobile welding system that Jolson has built for these applications. A soldier pile is a critical component of many highway projects in Northern California as soil makeup and varying terrain make earth retention necessary. On this particular project, beams of A709 bridge steel will be paired together and placed into holes drilled deep into the ground, serving as the structural backbone for a rebar and concrete retaining wall. Flux-cored arc welding (FCAW) is Jolson’s process of choice. There are structural steel welders who still rely on the shielded metal arc welding (SMAW, or Stick) process due to familiarity; however, flux-cored welding offers a number of advantages in terms of quality and productivity. “If you don’t want to get a lot done in a hurry, stick welding is the way to go,” says Jolson, “but running this process (flux-cored), the deposition rate is really high on it and you get a lot done in a day – probably five or six times more than you would with stick.” Engine-driven welder generator: Big Blue® 500 Voltage-sensing wire feeder: SuitCase® X-TREME™ 12VS Remote control: Wireless Remote Hand Controls Self-shielded flux-cored wire: Hobart Brothers Fabshield® XLR-8™ Self-shielded flux-cored welding gun: Bernard™ Dura-Flux™ Gun 1. Greater productivity through faster deposition rates — the .072-inch self-shielded flux-cored wire used in this application compared to a 7018 1/8-inch stick electrode provides approximately a 249-percent increase in deposition rate in the flat and horizontal positions, and a 162-percent increase in vertical up and overhead positions. 2. Greater deposition efficiency compared to stick electrodes — the flux-cored wire discussed in this case presents a 75-83 percent deposition efficiency versus 65-73 percent in a comparable 7018 stick electrode. 3. Low hydrogen weld deposit (provides resistance to cracking, promotes X-ray quality welds) — the wire used in this application features less than 8 ml/100g of diffusible hydrogen. 4. Welds out of position at high currents, also helping with productivity. 5. Less cleanup through simplified slag removal. Jolson’s power source preference is large-frame, low-speed diesel engine-driven welder generators. Jolson operates a number of Miller welder/generators, including the BigBlue 500. The Big Blue 500 is a CC/CV power source – necessary for flux cored welding – that provides 14-40 volts of welding output in MIG and flux-cored processes. “Our outputs will depend on what positions we’re welding in” says Jolson. “In flat positions we’ll run up around 23 volts and 300 inches per minute (ipm), and when welding vertical-up we run about 230, 240 ipm at about 22 volts.” In addition to providing adequate weld output, Jolson chose this welder/generator for its ability to work at low RPM. “We run the Big Blue engine drives because they run at 1,850 RPM, which helps us keep our fuel economy in check,” says Jolson. “I can get 35 to 40 hours of welding out of one tank of fuel.” Jolson also runs deluxe models that provide 20,000 watts 3-phase power and 12,000 watts 1-phase power in addition to the machine’s standard power. This gives them the ability to run common jobsite tools and accessories, as well as equipment with 3-phase input requirements such as pumps, plasma cutters and portable welders that help turn one machine into a multi-arc work station. “There have been a lot of times where we’re out on a pipeline job and we’ll have to plug in a three-phase pump to empty our ditch and be able to get down in there and do our welding,” says Jolson. “We also use that three-phase power to run our plasma cutters. They cut a lot quicker and everything stays nice and cool, as the duty cycle is increased (with the 3-phase power input power).” To give you an idea of how much welding goes into these structural projects, Jolson and colleague Brandon Hobbs burn through 40 to 45 pounds of wire each day, per man. To simplify inventory and handling, Jolson has standardized almost his entire structural operation on .072-inch Fabshield XLR-8 self-shielded flux-cored wire (AWS E71T-8JD H8). “We stick with the .072 because we could turn it way up or way down, we could weld anything from a handrail to a four-inch thick piece of pipe,” says Jolson. “One wire does it all. And it’s user-friendly. It’s not finicky. You could be a few volts off, or off on your ipm, and it still welds (to standards). ” The primary benefit of a flux-cored wire over a stick electrode is that it is continuously fed, whereas a stick electrode requires the worker to continuously start and stop to replace electrodes. This improves productivity and minimizes the possibility of defects caused by more frequent starts and stops. There is also a higher percentage of lost material with stick electrodes as filler metal in the stub is discarded. As such, 50 pounds of flux-cored wire compared to 50 pounds of stick electrodes would yield a higher deposition efficiency: more of the filler metal is actually deposited into the joint. That efficiency ranges from 75-83 percent with this particular wire compared to 65-73 percent with a 7018 stick electrode (when the product has been burned to a 2-inch stub). “It’s a real high deposition welding wire, and it’s very clean,” says Jolson. “Very seldom do you have any slag inclusions or porosity or anything like that.” The cleanliness Jolson refers to is due in part to easy slag removal. The slag produced by this wire is known to be self-peeling in many cases, improving productivity through less cleaning and helping to prevent potential defects caused by slag inclusions. It also features low levels of diffusible hydrogen (less than 8 mL/100g) and excellent mechanical properties for welding in seismic zones: 58 ksi minimum yield strength, 70 ksi minimum tensile strength, with 22 percent minimum elongation at 2 inches, and impact values of 40 ftlbs at 70 degrees Fahrenheit. “It has really great Charpy V-Notch impact values, and that’s important because of the critical work we do,” says Jolson. One of the concerns that face Flux-Cored welding applications in the field is the consistency of the wire feeding itself. Wire feed speed consistency is important in terms of controlling the deposition rate and heat input into the steel beam – voltage varies with the changing distance between the electrode and the work piece. The new Miller SuitCase X-TREME 12VS voltage-sensing wire feeder ensures wire feed consistency through new robust features and a design resilient to temperature swings throughout the day known to cause variations in feeder performance. “The new feeder is the smoothest feeder I’ve ever ran,” says Jolson. “They have a little bit bigger motor in them, so they don’t get hot throughout the day. (With other feeders), the weather gets hotter and the motor gets hotter in the feeder. The new 12VS is very constant and doesn’t change around. Wherever you put it in the morning, it’s there at the end of the day. There’s no variation.” The new feeder features a new drive motor assembly, motor control and integrated tachometer that provides electronic wire feed speed control and accuracy that rivals the performance of bench-top-style feeders found in shop environments. A new wire delivery system makes it easier to load the 12-inch wire spools and reduces drag on the wire by eliminating the inlet guide and allowing the wire to roll over the large radius of the drive rolls. It also features a new visual scale on the wire pressure knob that eliminates guesswork and allows welders to specifically dial in tension to settings they know provide the best feeding performance for the size and type of wire they are working with. “Having the register on the scale is nice because you always know where you need to be,” says Jolson. “If somebody messes with your machine or puts different wire in it, you just dial it in and you’re up and running. You don’t have to guess and turn it a half-turn and back a half-turn. It makes it really user friendly.” Jolson also claims the feeders allow him to more easily load in new spools of wire, and switch between different wire types/diameters through the elimination of guide tubes within the feeder. “In the old days, we had to change out guide tubes (when changing wire diameters),” he says. “There is no guide tube on this feeder. You just open your feeder, feed your wire through right into the gun, cinch her down and you’re ready to go.” A focus of welding manufacturers has been to put as much knowledge and power into the hands of the welder at the point-of-use as possible. In an application like this, that includes the ability to know exactly what your machine settings are and to change them without having to go back to the welder/generator at the truck. Two technologies that help Jolson with this are digital meters on the wire feeder and wireless remote control technology matched up with the welder/generator. Together, these technologies help improve productivity by allowing welders to more quickly dial in their equipment and get to work faster. “The (wire feeders) without the digital meters, you have to call over to your buddy to tell you where the needle is bouncing around at, and you’re never really accurate that way,” says Jolson. “With this feeder, you can make a practice pass, let off the trigger and look over (at the feeder) and it will hold its values. That way you know where you’re at and you don’t have to bother your partner to come and help you. You can really see them good, too, out in the sun. It’s got some special technology in there that, even out on a sunny day, you can still see your numbers – and that’s nice.” With a voltage sensing wire feeder and CV power source, voltage is set at the power source while wire feed speed (amperage) is set at the feeder. In the past, after running his test pass, Jolson would have to get up and go back to the truck to adjust his voltage. Now, with wireless remote technology, Jolson has full control of that setting without leaving his workplace. “If I’m up on a ladder and I’ve got to change my settings, I don’t want to crawl up and down all day,” says Jolson. “If I’m down in a ditch and I’ve got to turn the machine up and down, rather than spending ten minutes crawling in and out of there, I can turn it up or down and I’m good to go.” Rounding out Jolson’s structural welding system is the Bernard Dura-Flux Self-Shielded Flux-Cored Gun, built specifically for self-shielded flux-cored welding. Rated at 350 amps, these guns feature ergonomic handles, easy-change consumables and a “We like the long goosenecks because it keeps us away from the heat,” says Jolson. “And this sealed microswitch, If you’re out in a dusty environment where it’s laying on the ground all the time, it never gets any dirt or dust in it and it continues to work perfect every time.” “I like the Bernard gun – how you hold it in your hands,” says Hobbs. “You don’t have any fingers that are pressed together, squeezing together, pinching themselves off, getting all tingly and numb. It’s easy to hold and move around. It’s comfortable in the grip of your hand and the trigger guard isn’t too bulky – it does its job without messing you up, without hindering your performance.” Jolson also likes the ability to change out the contact tip without tools – a technology that Bernard calls its Centerfire™ Consumable System. “You take off the little retainer, the tip comes out and you replace your tip,” says Jolson. “And, normally, the tip always wears the top and the bottom, it wears a groove in it. (With these) you can loosen this up, turn the tip 90 degrees, tighten it back down and you’ve got a brand new tip again – so you get two lives out of one tip.” When put together, these varied components build a structural steel welding system that Jolson finds to be optimal for the work he does, ranging from bridge construction to pile splicing. Knowing that all of these components are designed by companies that work together to provide best-in-class, market-focused solutions, Jolson has peace of mind that he’s going to work with the best tools available. “It’s nice because everyone seems to work together,” says Jolson. “If I have a problem with my wire and I’m talking to a Miller representative, they can help me out and vice versa. With Miller, Bernard and Hobart Brothers working together, it really helps us out as end users because everybody knows a little about everything. There’s always somebody there to help you out.”
New industry standards from the Occupational Safety and Health Administration (OSHA) are protecting employees against potential health hazards in the workplace. These regulations, which dictate allowable exposure limits of welding fumes and other particulates (including hexavalent chromium), have led many companies to invest in fume extraction equipment. An increased desire to maintain optimal welding operator safety and to attract new skilled welding operators to the field is also a consideration in investing in this equipment — companies want to create the most comfortable and healthy work environment possible. Some companies may opt for centralized fume extraction systems, which are designed to protect the entire shop area. These systems involve the installation of new ductwork Fume extraction guns are available in a variety of amperages, cable styles and handle designs. As with any welding equipment, they have their advantages and limitations, best applications, maintenance requirements and more. In combination with many other variables in the welding operation — welding wire selection, specific transfer methods and welding processes, welding operator behavior and base material selection — fume extraction guns can help companies maintain compliance with safety regulations and create a cleaner, more comfortable welding environment. Fume extraction guns operate by capturing the fume generated by the welding process right at the source, over and around the weld pool. Various manufacturers have proprietary means of constructing guns to conduct this action, but at a basic level they all operate similarly: by mass flow, or the movement of material. This movement occurs by way of a vacuum chamber that suctions the fumes through the handle of the gun, into the gun’s hose through to a port on the filtration system (sometimes informally referred to as a vacuum box). The welding fumes that these guns remove are composed of a combination of the filler metal and base material. Some fume extraction guns feature adjustable extraction control regulators at the front of the gun handle, which allow welding operators to increase suction as needed (without affecting shielding gas coverage), while others provide this function internally. Regardless of the manner, the ability to balance between the downward flow of shielding gas and the upward flow of the suctioned air is critical. The fume extraction gun needs to provide the appropriate amount of shielding gas to protect the weld from defects such as porosity, without sacrificing the ability to suction fumes efficiently enough to protect the welding operator. The balance allows the weld pool time to react and solidify, and gives the fume particles time to decelerate so they are easier to extract. Typically, fume extraction guns are larger than regular welding guns and tend to be bulky due to the vacuum and hose necessary to extract the fumes. For that reason, some manufacturers create fume extraction guns with a vacuum hose swivel on the rear of the handle to make them easier to maneuver. Manufacturers have also, since fume extraction guns were first introduced (in the late 1960s and early 1970s), found ways to engineer internal components to minimize the handle weight in order to reduce operator fatigue. Fume extraction guns are well-suited for applications using solid welding wire and those in confined spaces. These include, but are not limited to applications in the shipbuilding and heavy equipment manufacturing industries, as well as general manufacturing and fabrication. They are also ideal for welding on stainless steel applications, as this material generates greater levels of hexavalent chromium, and on mild and carbon steel applications. The guns also work well on high amperage and high deposition rate applications and are available, typically, in 300 to 600 amp ranges. For the best results, fume extraction guns should be used for in-position welding, such as on flat butt welds. In this position, they can most effectively capture fume particles as they rise from the weld pool. In out-of-position welds, the energy of the fume particles causes them to rise at a high rate, making it more difficult for the fume extraction gun to draw them downward and through the vacuum hose. One distinct advantage to fume extraction guns is that they remove the fumes at the source. This will minimize the amount that enters the welding operator’s immediate breathing zone. However, because welding operators typically move the gun away from the weld pool after completing a pass, the fume extraction gun is not as able to control residual fume as well as a fume extraction hood can. As with any piece of welding equipment, fume extraction guns benefit from preventive maintenance. Caring for them is similar to caring for a standard GMAW gun. Regularly check for tight connections throughout the length of the fume extraction gun to ensure good electrical flow. Minimizing electrical resistance helps ensure consistent weld quality and prevent premature failure of the front-end consumables — contact tip, nozzle and diffuser. Frequently inspect the nozzle and contact tip for signs of spatter build-up, too, as such build-up can obstruct shielding gas flow and cause weld defects that ultimately will need to be reworked. Spatter build-up can also cause consumables to fail prematurely. Replace the consumables if spatter build-up appears or clean them according to the manufacturer’s recommendation. In some cases the shroud that surrounds the nozzle may also have to be replaced or cleaned free of spatter. To ensure optimal fume extraction capabilities, inspect the vacuum hose regularly for damage, including cuts or kinks that could lead to loss of suction. Replace a damaged vacuum hose as necessary and dispose of it according to the manufacturer’s and/or an industrial hygienist’s directions. Visually inspect the handle for cracks or missing screws, and also check that the gun’s trigger is not sticking or otherwise malfunctioning. Replace or repair these components as necessary. Finally, maintenance on the liner is also important. As with the vacuum hose, use compressed air to clear out any potential blockages during welding wire changeovers or when removing the wire from the gun. Spending an extra few minutes clearing out any debris from the liner can save considerably more time than troubleshooting the weld defects and equipment problems that can result from blockages. Also, track the amount of time that it takes for a liner to wear during the course of the welding operation. Replace the liner prior to that in the future to prevent downtime for replacement during shifts or problems with wire feeding or quality. When in doubt about maintenance or any other aspect of using a fume extraction gun, consider working with a trusted welding distributor, certified industrial hygienist and/or the fume extraction gun manufacturer to address any questions or concerns. Proper use of this equipment can help provide optimal results, and improve the safety and comfort of the welding environment.
In the fabrication and manufacturing world, quality and productivity are everything. To remain competitive, companies need to look continually for ways to increase throughput and minimize defects, while also keeping costs low for parts and labor. In many cases, turning to robotic welding is a means to achieve those goals — for both the smaller job shop and larger manufacturing facilities. The decision to implement a robotic weld cell, however, takes a good deal of consideration and planning if the system is to function in the most efficient, productive and profitable manner. And it requires a significant investment. Fortunately, the long-term benefits of a robotic welding operation can be very positive. For companies who have already invested in robotic welding, but are looking to improve or better understand their operations, or for those considering the investment, it is critical to consider some key factors about the technology. Here, we will explore “what you must know about robotic welding” to make the most of the process. Justifying the cost of a robotic weld cell comes down to the ability to gain (and prove) a payback on the investment. Typically, that payback comes in the form of greater productivity and higher-quality welds (which minimize instances of costly and time-consuming rework), but there are other contributing factors to the return on the investment (ROI) in this technology. Robotic welding also offers the advantage of lower energy and labor costs, and in many cases lower material costs due to fewer instances of overwelding. Overwelding is a common and costly occurrence in semi-automatic welding. A weld bead that is 1/8-inch larger than necessary can double filler metal costs, but a robot can reduce those costs by only putting down as much material as necessary. Plus, robotic welding systems use bulk filler metals (600-pound drums, for example) that companies can often purchase at a greater discount. For companies just considering the investment in robotic welding, it is important to consider how to calculate the payback. Assess the current part cycle times and compare those to the potential cycle times of a robot. A trusted robotic welding integrator or OEM can often help with this calculation. During this process, also consider the possibility of reallocating existing labor to other parts of the welding operation, where these individuals can add value to the process. Remember, up to 75 percent of the cost in a semi-automatic welding operation is labor. If there is the opportunity to use that labor elsewhere to increase part production, the payback on the investment in robotic welding will increase. Most companies — particularly smaller ones or those with frequent production changes — seek a payback on the robotic welding investment of no greater than 12 to 15 months. That time frame is entirely possible to achieve with proper up-front planning of the part blueprints, fixturing and general setup of the system. In some cases, companies may be able to justify a longer payback period if they know that their production needs will remain relatively static for longer periods of time. The output from a robotic welding cell is only as good as the parts fed into it. In order to gain the advantages of these systems, it is critical to have accurate, repeatable part designs. Gaps, poor fit-up or poor joint access all prevent a robot from completing its job correctly. The best part designs for a robotic welding application are simple ones that allow the robot to execute the same weld repeatedly. High-volume applications with low-variety parts are especially poised to gain the advantages of robotic welding. Companies should try to avoid part designs that require intricate tooling or clamping to hold it in place, as both can hinder the efficiency of the robot and also add to the up-front cost of the operation. That said, in some cases, companies may still be able to gain a good payback on the investment in tooling for slightly more complex parts, but they will need to weigh out the pros and cons of that cost ahead of time. Companies also need to be certain to assess their overall welding operation for consistent process flow. Bottlenecks upstream can easily slow down the movement of parts into the robotic work cell and the ability of the system to function to its full capacity. A robot that sits idle costs time and money. Some companies may need to reconfigure operations or set up a flexible cell that can manage quick tool and fixture changes in order to minimize bottlenecks in the process flow. It is also important to have adequate labor to supply the robot with parts. Again, companies should consider tapping the knowledge of a robotic welding integrator for advice and assistance to optimize process flow. The robotic MIG gun and consumables on a robot together are responsible for directing the current to the arc to complete the weld, making them integral components in the whole system. To gain the best quality and to avoid expensive downtime for maintenance, repairs or replacement, companies need to select a robotic MIG gun that is suitable for the amperage, duty cycle and cooling capacity needed in the application. Using a robotic MIG gun that offers inadequate cooling or amperage can cause performance issues and lead to premature failure — both factors that increase costs and downtime. Likewise, using a robotic MIG gun that offers higher amperages than necessary raises the total cost of ownership, as typically the cost of a robotic MIG gun increases directly in proportion to its amperage. Companies also need to select their consumables — contact tips, nozzles, retaining heads (diffusers) and liners — carefully and manage them properly in order to gain optimal productivity and lower costs. Look for contact tips with more mass at the front end and that are buried further in the gas diffuser — both features help the tip resist heat from the arc. Consumables with tapered connections mate securely together to provide good electrical conductivity, which also reduces heat buildup and helps the consumables last longer. Contact tips with long tails and coarse threads are also a good option to simplify installation — they virtually eliminate cross-threading because the tail concentrically aligns the contact tip within the diffuser before the threads engage. This easy-to-install design works well for operations with less experienced welding operators who may not be as familiar with consumable changeovers. It also helps reduce unplanned downtime for troubleshooting associated with cross-threading. As with robotic MIG guns, carefully matching the type of consumables to the application can keep companies from having to address premature failures and/or accrue costly downtime (not to mention, lapses in production). It can also keep them from overpaying for consumables that may be too much for the application. Companies should also consider the mode of welding when selecting consumables, as technology such as Pulsed welding tends to be especially harsh on consumables and often requires heavy-duty options to withstand the heat of the arc for longer periods of time. For these applications, look for contact tips that are engineered with a hardened insert, making them more resistant to arc erosion and wear. They typically last 10 times longer than copper or chrome zirconium tips. Companies can regain as much as 95% of lost productivity for contact tip changes with this style by reducing planned downtime for the task. Peripherals refer to any additional equipment integrated into the robotic welding system to maximize its performance. They include items such as a nozzle cleaning station (sometimes called a reamer or spatter cleaner), anti-spatter sprayers, wire cutters and neck alignment tools. Unfortunately, some companies downplay the value of peripherals, viewing them as an unnecessary cost, and don’t realize that they can play an important role in reducing downtime and rework, improving quality and increasing productivity. Consider a nozzle cleaning station, for example. As its name implies, this peripheral cleans the nozzle of dirt, debris and spatter, typically during routine pauses in the robotic welding operation. This cleaning action helps prevent shielding gas coverage loss that could lead to weld defects, expensive rework and lost productivity. The equipment also helps the front-end consumables last longer — and longer consumable life means less downtime for changeover and less expense for replacements. The addition of an anti-spatter sprayer further improves consumable life and performance by adding an anti-spatter compound that serves as a protective barrier against spatter buildup and other contaminants. In the long run, the up-front investment in peripherals such as these can lead to measurable savings and provide a better return on investment by aiding the robot in doing what it does best: complete consistent, high-quality welds for longer periods of time than a semi-automatic welding operation. Robotic welding operations require ongoing supervision and maintenance, and that job needs to be completed by a skilled operator who has undergone the proper training. When considering an investment in robotic welding, companies should take care to evaluate the available pool of talent. As a rule, skilled welding operators and/or employees with prior robotic welding experience are the best candidates to supervise the weld cell. After the proper training, which a robotic integrator or OEM can typically provide, these employees can provide the necessary operating and troubleshooting skills to ensure the maximum uptime in the robotic welding cell. As part of the routine training, it is absolutely necessary for the operators who will be overseeing the robot to be able to schedule and perform routine preventive maintenance on the system. Implementing preventive maintenance helps minimize unnecessary downtime and keep the robotic welding system running more smoothly. If problems can be solved before they arise and the robotic welding equipment made to last longer, it can protect the company’s investment, and ensure the productivity and profitability sought by this equipment in the first place. Companies should consider vetting robotic welding integrators to determine the availability and costs associated with the training of personnel. Typically training lasts one to three weeks, depending on the certification level desired, and continuing tutorials are often available. In the end, careful planning, good equipment selection and proper training are all “must-knows” for managing a profitable and productive robotic welding operation. So whether a company is new to robotic welding or trying to improve an existing operation, knowing some key factors can go a long way in helping to gain a competitive edge and to make the most out of the investment.
The term “ergonomics” has become increasingly common in the workplace as companies strive to improve safety and efficiency among employees — whether in the office or on the plant floor. At its most basic level, ergonomics refers to the discipline or science of designing equipment and arranging the work environment for optimal worker comfort and productivity. Minimizing fatigue, reducing repetitive motion, and decreasing overall physical and mental stress are some of the key factors at the heart of it. For welding operators who spend their time maneuvering around difficult weld joints with a MIG, flux-cored or fume extraction welding gun and facing a hot arc, the term takes on an especially important meaning. A welding gun’s handle, neck and power cable design can significantly impact the duration of time a welding operator can weld without experiencing fatigue or stress. So too can the heat generated in the process. Excessive heat, just like musculoskeletal strain, can contribute negatively to the welding operator’s health and efficiency. In the long run, choosing a welding gun that offers greater comfort and operates at a cooler temperature can help increase productivity and, ultimately, the profitability of the welding operation by allowing for greater arc-on time. When welding, the first factor in good ergonomics is to select a welding gun with the appropriate handle design. Typically, manufacturers offer handles in curved and straight designs, one or the other of which may be more comfortable for a given welding operator to hold and control. The preference is individual and a welding operator may need to experiment to determine which design best suits him or her. If possible, a welding operator may want to consider using a slightly lower-amperage welding gun to gain greater comfort and minimize fatigue and/or stress on the wrists and hands. Typically, as a welding gun’s amperage decreases, so too does the size of the gun handle, which makes the equipment lighter and easier to maneuver for longer periods of time. It is important, however, that in selecting a smaller and lighter-weight handle, the welding operator still has a gun that meets the application’s amperage and duty cycle requirements. Duty cycle is defined by the amount of arc-on time in a 10-minute period that the equipment can be operated at maximum capacity. Some welding guns will offer 100 percent duty cycle, while others are rated 60 percent or below. In many cases, a welding gun rated at 300 amps, for example, may suffice for a 400-amp application considering that welding operators rarely weld continuously enough to exceed the gun’s duty cycle. In a shop setting, another option to gain greater comfort and productivity would be to convert to a water-cooled welding gun for MIG applications, as these guns are generally smaller, lighter and easier for welding operators to manage for longer periods of time. Smaller, shorter and lighter power cables offer greater flexibility to welding operators, making it easier to maneuver the equipment without excess stress on the wrists or hands. A good rule of thumb is to select the smallest and shortest power cable possible that can still meet the needs of the application. Smaller, shorter power cables can also minimize clutter in the weld cell by preventing excessive coiling and minimizing tripping hazards. Less clutter and coiling also reduces the chance of poor wire feeding that could cause downtime and hinder productivity. On fume extraction guns, look for vacuum hose swivel on rear of handle, as this feature improves flexibility and reduces welding operator fatigue. Many MIG and flux-cored guns are available with rotatable and flexible necks in various lengths and angles. These types of necks allow the welding operator to select one that will best suit the joint access required for an application. For example, rotatable necks are a good option for welding out of position, even overhead. They do not require the welding operator to change the welding gun handle or position, so he or she can hold the gun in a way that is most comfortable, while also gaining access to the weld joint. Similarly, flexible necks can be easily adjusted to fit different welding angles and reach difficult joints that may be restricted or otherwise awkward to reach. This feature also helps minimize straining to reach a particular weld joint, and with it reduces the opportunity for fatigue or injury. Some welding gun manufacturers also offer neck couplers. These accessories allow the welding operator to connect multiple necks together to reach especially difficult joints more comfortably. Increasing productivity in a welding operation by way of improved ergonomics is a matter of more than just having lightweight, easy-to-control equipment. It’s also a matter of minimizing heat stress in the work environment. When welding materials such as aluminum or stainless steel, there is an opportunity for greater radiant heat — heat that reflects from the welding arc and base metal back to the handle. Welding operators can use a longer neck on the welding gun to place the handle further back from the arc when welding on such applications. Also, the addition of a neck grip on a MIG gun can protect the welding operator from heat exposure and related fatigue. These high-temperature silicon rubber grips slide over the neck and offer the added benefit of increased control. They allow welding operators to rest the neck on their hand or forearm, using it as a pivot point to maneuver the MIG gun more comfortably. In the end, having equipment that is easy to operate during the welding process is the first step in achieving good ergonomics, a safe work environment and greater productivity. After all, a more comfortable welding operator is a more content one. And more content employees can help companies generate greater throughput on a day-to-day basis. Start the process by finding welding guns that are lightweight, offer an appropriate handle and neck design, and feature the right neck and power cable for the job and for the welding operator.
April 1, 2013 Introducing the next evolution of the TOUGH GUN® reamer from Tregaskiss. Improvements to the sprayer system, new plug and play replacement parts, and simplified internal wiring make this new reamer more reliable and faster and easier to maintain than ever before! Learn more about the TOUGH GUN TT3 reamer and how it benefits both your bottom line and your production uptime and throughput.
Employees at Jolson Welding work on tough structural pile and pipe welding projects and have come to rely on the durability and comfort of the Bernard Dura-Flux self-shielded flux-cored gun to increase productivity. “I like how the handle is shaped and how your hand fits around it. The gun contours your hand and glove, not cutting off the circulation to your fingers because of how they’re offset. The trigger guard isn’t too big to where your hands are hitting it or grabbing on everything. It’s just big enough to keep the trigger from getting hit and out of your way. This Bernard Dura-Flux gun’s got what they call a micro switch in it, so it’s a sealed switch. These are bulletproof. If you’re out in a dirty environment where laying on the ground all the time like ours it never gets any dirt or dust in it. It continues to work perfect all the time. The Centerfire is really nice because you don’t need tools to get the tip off.” PRODUCT UPDATE – New Handle Names for the BTB MIG Gun Platform
PRODUCT UPDATE –
New Handle Names for the BTB MIG Gun Platform
Beginning on June 2, 2014, Bernard’s new Best of the Best Platform brings our Q-Gun™, S-Gun™ and T-Gun™ semi-automatic air-cooled MIG guns into a single gun line and single configurator. Since we now have six gun handle styles within a single configurator, we have developed the following naming scheme for our handles per the chart below:
PRODUCT IMPROVEMENT – Q-Nut for BTB MIG Guns
PRODUCT IMPROVEMENT –
Improved Q-Nut Launching with the BTB MIG Gun Platform
SYSTEM UPDATE – New Gun Part Numbers for BTB MIG Guns
SYSTEM UPDATE –
New Gun Part Numbers for BTB MIG Gun PlatformAll Bernard Semi-Automatic Air-Cooled MIG Guns under the new BTB Platform will have new part numbering as of June 2, 2014.
Gun Line Old Part Number New Part Number Selecting Consumables for Robotic Welding and Making Them Last
Selecting Consumables for Robotic Welding — and Making Them Last
General selection considerations
Space and duty cycle factors
Nozzle maintenance
Storage and handling
Proper connections
and gas diffuser (as shown in this cutaway)
help ensure reliable electrical conductivity
and minimize heat. The result is more
consistent weld quality and longer-
lasting consumables.Quality of Consumables Can Play a Role in Welding Productivity, Costs
Quality of Consumables Can Play a Role in Welding Productivity, Costs?
This article has been published as a web-exclusive on thefabricator.com. To read the entire story by Bernard design engineer Rob Centner, please click here.
Attacking Weld Fume at the Source
Attacking Weld Fume at the Source
maintain compliance with safety regulations
and create a cleaner, more comfortable welding
environment. Proper use and maintenance of the
equipment is important to get optimal results.The basics
Benefits of fume extraction guns
Watch the degree of angle
the welding process right at the source, over and around the weld
pool. As with any piece of welding equipment, fume extraction
guns benefit from preventive maintenance.Flux-cored wire allows vacuum adjustment
Pause at the end
Wire type determines stickout
Experiment with the air control regulator
Proper maintenance and consumable usage
Fume extraction guns can provide results
PRODUCT UPDATE – New Internal Stop in Centerfire and Quik Tip Diffusers
PRODUCT UPDATE –
New Internal Stop in Centerfire and Quik Tip Diffusers
What’s Changed?
Frequently Asked Questions
PRODUCT IMPROVEMENT – Tregaskiss Cutter Blades
PRODUCT IMPROVEMENT —
Tregaskiss Cutter Blades
Ordering Information
Part Number Cutter Blade Nozzle RCT-01 0.500″ (12.7 mm) Cutter 5/8″ (15.9 mm) Bore RCT-04 0.358″ (9.1 mm) Cutter 1/2″ (12.7 mm) Bore RCT-05 0.375″ (9.5 mm) Cutter 1/2″ (12.7 mm) Bore, TOUGH ACCESS™ RC-06 0.281″ (7.1 mm) Cutter 3/8″ Bore RC-08 0.438″ (11.1 mm) Cutter 5/8″ (15.9 mm) Bore, Binzel® RCT-10 0.406″ (10.3 mm) Cutter 5/8″ (15.8 mm) Bore, TOUGH ACCESS RCT-11 0.562″ (14.3 mm) Cutter 11/16″ (17.5 mm) Bore, Tandem RC-12 0.530″ (13.5 mm) Cutter 3/4″ (19.0 mm) Bore RCT-13 0.520″ (13.2 mm) Cutter 3/4″ (19.0 mm) Bore RCT-16 0.359″ (9.12 mm) Cutter 15.5 mm, Panasonic®, 350 amp RCT-17 0.359″ (9.12 mm) Cutter 16.0 mm, Panasonic, 500 amp RCT-18 0.500″ (12.7 mm) Cutter 15.5 mm Nozzle M10 Tip WH500T Torch, Binzel
NOTE: The TOUGH GARD spatter cleaner will be discontinued effective December 31, 2014Part Number Cutter I.D. Nozzle Bore C-500 0.350″ (8.9 mm) Cutter 0.500″ (12.7 mm) Bore C-625 0.500″ (12.7 mm) Cutter 0.625″ (15.9 mm) Bore C-PA001 0.359″ (9.12 mm) Cutter 15.5 mm, Panasonic, 350 amp C-PS002 0.359″ (9.12 mm) Cutter 16.0 mm, Panasonic, 500 amp C-Q001 0.359″ (9.12 mm) Cutter 9/16″ (14.3 mm) Bore, AWQ C-750W 0.520″ (13.2 mm) Cutter 0.750″ (19.0 mm) Bore, 600 amp Water-Cooled Preventive Robotic MIG Gun Maintenance: the Whos, Whens, Whys and Hows
Preventive Robotic MIG Gun Maintenance: the Whos, Whens, Whys and Hows
PM program basics: the whos and whens
Taking action: the whys and hows
Secure connections on a regular basis
Prevent spatter build-up
Mind the liner
Assess the welding cable and power pin
Parting thoughts on PM programs
From Technology to Technical Support: Welding in Today’s Automotive Industry
From Technology to Technical Support: Welding in Today’s Automotive Industry
What You Should Know About Shielding Gas
What You Should Know About Shielding Gas
The role of shielding gases
Selecting the right shielding gas
Tips for getting the most out of your shielding gas
Emergency Vehicle Service Provider Gains Versatility, Comfort and More from New Welding MIG Guns
Emergency Vehicle Service Provider Gains Versatility, Comfort and More from New Welding MIG Guns
New guns offer greater versatility and comfort
The added benefits of new consumables
Keeping the customer happy is priority No. 1
PRODUCT IMPROVEMENT – New Swivel Design on the Bernard FILTAIR Fume Extraction Gun
PRODUCT IMPROVEMENT –
New Swivel Design on the Bernard FILTAIR Fume Extraction GunWhat Changed?
Frequently Asked Questions
PRODUCT IMPROVEMENT- Tregaskiss Automatic MIG Gun Series Handles
PRODUCT IMPROVEMENT —
Tregaskiss Automatic Series MIG Gun Handles
10 Money Saving Tips for Your Semi-Automatic MIG Guns
10 Money Saving Tips for Your Semi-Automatic MIG Guns
Tip No. 1: Protect Your Assets
Tip No. 2: Get a Neck Up
Tip No. 3: Inspect, Clean and Tighten Regularly
Tip No. 4: Trim It Properly
Tip No. 5: Line It Up
Tip No. 6: Lighten Up
Tip No. 7: Stay Connected
Tip No. 8: Keep It Smooth and Clean
Tip No. 9: Size It Right
Tip No. 10: Think Long Term
7 Things To Know About Robotic Welding Systems
7 Things To Know About Robotic Welding Systems
1. Part repeatability is critical to successful automation
2. Training is essential
3. Additional safety equipment may be necessary
4. Weld data monitoring and/or peripherals can help improve results
Proper maintenance can help protect the investment in automation
6. Communication is key to proper weld quality and cost savings
7. Robots can do more than just weld
Preventive Maintenance Isn’t Just for Welding Robots
Preventive Maintenance Isn’t Just for Welding Robots
Preventive Maintenance Tasks
1. Check connections on a regular basis
2. Regularly inspect the welding cable and power pin
3. Look for spatter build-up.
4. Replace the liner ahead of failures.
The Frequency and Scope
Jolson Welding
Heavy Structural Welding Simplified with Low-Speed Diesel Welder/Generators, Low-Hydrogen Flux-Cored Wire, Flux-Cored Guns and New Wire Feeding Technology
The System:
Advantages of Self-Shielded Flux-Cored Welding
Building a Welding System: The Power Source
Wire Standardization Drives Quality, Productivity
New Feeder Technology Improves Feeding Consistency
Setting Parameters Simplified Through Digital Meters, Wireless Remotes
Specialized Flux-Cored Guns Take the Heat, Provide Optimal Comfort
robust design for working in hot and dusty outdoor applications.Fume Extraction Guns: Understanding the Basics
Fume Extraction Guns: Understanding the Basics
The basics of fume extraction guns
Applications, advantages and limitations
Maintenance tips
What You Must Know About Robotic Welding
What You Must Know About Robotic Welding
1. There’s more to the payback on a robotic welding system than just speed
2. Parts and product flow need to be consistent
3. The MIG guns and consumables on the robot can impact productivity and profitability
4. Peripherals can help improve the return on investment in a robotic welding operation
5. Having skilled operators with proper training to oversee the robotic weld cell is critical
The Value of Comfort: Gaining Productivity with the Right Welding Gun
The Value of Comfort: Gaining Productivity with the Right Welding Gun
Minimize fatigue with the right handle
Keep power cables short, small
Reduce strain with the right neck
Staying comfortable by staying cool
NEW PRODUCT – TOUGH GUN TT3 Reamer
NEW PRODUCT —
TOUGH GUN TT3 ReamerMore Reliable and Easier to Maintain Than Ever Before!
Welding contractor shares benefits of Bernard Dura-Flux Self-Shielded Flux-Cored Gun | Customer Testimonial
Welding contractor shares benefits of Bernard® Dura-Flux™ Self-Shielded Flux-Cored Gun
