Ethernet vs Standard Reamer: Making the Selection 

Uptime is key in any robotic welding system. Not only does it help companies increase productivity, but it also supports a solid return on investment in the equipment. The addition of peripherals, like a nozzle cleaning station or reamer, can help further those goals.

A reamer cleans the consumables on a robotic gas metal arc welding (GMAW) gun to prevent spatter buildup that could lead to porosity. This consumable cleaning reduces downtime for changeover, improves weld quality and minimizes costs. There are two main styles to choose from: standard- or Ethernet-based. Both provide the same function of cleaning the nozzle free of spatter, with the Ethernet-based reamer providing additional functionalities that some companies find beneficial to their robotic welding operation.

During cleaning, the robot is programmed so that it will dock the nozzle of the GMAW gun against a v-block on top of the reamer, typically during routine pauses in welding cycles. Once the nozzle is in place, a signal is relayed to the reamer to close its clamps. When the clamps hold onto the nozzle, concentric to the cutter blade, another signal is sent to the unit telling the spindle to rise and spin the cutter blade, removing the spatter from the nozzle and gas diffuser.

Many companies also employ an anti-spatter sprayer that applies a coating of anti-spatter compound to the front-end consumables after every cleaning cycle. Usually this spray only lasts a half second to avoid saturating the nozzle and wasting the anti-spatter compound.

Standard versus Ethernet

A standard reamer features inputs and outputs that are plugged into a Program Logic Controller (PLC), including the inputs that control the nozzle clamping, cutter actions and anti-spatter spray process. These are the traditional reamers used by many companies.

A standard reamer must be plugged in with a power cord, in addition to having several leads connected to several inputs and outputs, so it may require cord management to minimize clutter.

Ethernet reamers, a newer style, feature a single Ethernet cable that serves as a multipurpose input/output and connects to the PLC. Due to their connectivity, they enable robotic welding system operators to set a program that handles complex equations so they can easily duplicate that program to another weld cell.

Consider a robotic welding operation featuring 100 weld cells that require 50 reamers total. If there are two robots per cell sharing the same reamer, and the reamer program for all 100 weld cells is virtually identical to the first cell, operators can set the program in the first cell to alternate between the two robots and then essentially “copy and paste” that program into the next 99 cells. For this reason, an Ethernet reamer can offer time savings, especially at the integrator level.

With an Ethernet reamer, robotic welding operators can also program a double stroke. If one cleaning cycle wasn’t quite enough to remove spatter from the nozzle, a signal is sent, as the spindle unit and cutter retract, to clean again.

Ethernet reamers can come with an additional Ethernet port, which can be used to daisy chain to other Ethernet devices. This means an operator does not require an individual Ethernet cord run from the reamer to the PLC, from the robot to the PLC, or from the power source to the PLC. He or she can instead run them in a series, together. This cuts down on the number of wires and cords in the cell, further reducing clutter. They also allow operators to monitor the cycle times carefully and more easily troubleshoot any issues that arise.

That said, some older robotic welding operations are not Ethernet-ready because they use standard-based signals, and some facilities simply do not have the infrastructure, resources, capabilities or knowledge necessary to justify the higher investment of an Ethernet reamer.

As with the implementation of any robotic welding system, having a champion with a certain skillset who can oversee the implementation of an Ethernet reamer and know how to program it is incredibly helpful, and it can ensure the success of the investment.

Regardless of which style of reamer is used, standard- or Ethernet-based, it should always be programmed with the gun docking to the reamer and the height set properly, following the instructions outlined in the owner’s manual. Always dock the nozzle concentric to the cutter, and always supply the reamer with clean, dry air.

Robotic reamer accessories

Almost all reamers function the same way, but accessories can be added to make them behave differently or optimize them for a welding operation.

Wire cutter attachments, for example, cut the wire stick out to a set distance so that the robot can employ wire-touch sensing. Most operations that use a wire cutter on the reamer also use a wire brake on the GMAW gun. The wire brake then holds the wire in place at that set distance so it can’t move — keeping it from extending or retracting as the robot moves. The wire brake works well in combination with robots employing touch sensing, as it keeps the wire in a set position while the robot searches and accurately locates the weld joint.

Lubricators are yet another valuable reamer attachment. A lubricator applies oil to the air motor impeller, coating the blades so they will not absorb moisture that might be present in the air. Keeping these blades lubricated helps extend the life of the motor and protect a company’s investment in a reamer.

Reamer stands are another accessory that can be useful. They are essentially a pedestal that an operator can mount the reamer to, with a stand bolted into the floor. Options exist in the marketplace that can be customized to a specific height to help streamline the weld cell layout and those that feature quick-change base plates to facilitate reamer change-outs when necessary.

Spray containment units are also common reamer attachments designed to keep the welding cell clean of anti-spatter compound. A spray containment unit is a cylinder that mounts on top of the sprayer head to keep excess anti-spatter spray from bleeding into the open environment in the weld cell.

Another useful reamer accessory is a nozzle detect, which is a proximity switch that detects whether a nozzle is present or not. Occasionally, when a robot enters its ream cycle, there may not be a nozzle present on the GMAW gun; it may have been bumped off during routine movement of the robot arm or from accidentally hitting a fixture. Nozzle detect will recognize the absence of the nozzle or if a nozzle is pulled off during a cleaning cycle. These occurrences are especially prevalent when an operation is using a slip-on nozzle, which is more likely to disconnect.

For large robotic welding operations, a multi-feed anti-spatter sprayer system may also be useful. This attachment allows up to 10 reamers to be working off one larger container of anti-spatter compound, eliminating the need for an operator to go into the cell and fill up the smaller sprayer reservoirs attached to every reamer. This reduces how often anti-spatter levels must be checked and the associated downtime.

Although all these accessories, and the reamer itself, do add to the cost of a robotic welding system, they can also lead to measurable cost savings and profits in the long run. Remember, the goal in robotic welding is repeatability and increased productivity, and any additional equipment that can help achieve these results may be worth the investment.

In the end, reamers help clean GMAW gun consumables and prevent porosity. They also reduce downtime and labor for changeover. Since cleaner nozzles and other consumables produce cleaner welds, they can help a robotic welding system produce higher-quality products and be more productive.

Extra: Reamer maintenance

While reamers and their attachments are often afterthoughts for many operators, maintaining them properly and ensuring parts are replaced promptly can greatly improve a robotic welding operation’s overall efficiency, quality and productivity.

All limit switches on a reamer have a life expectancy and must be replaced if they don’t activate any longer, for the reamer to work properly.

Cutter blades also need to be replaced, since the edges will become dull over time and will no longer cut as effectively. In some cases, an operator might visually see that one of the flutes on the cutter is broken.

Operators must also monitor the reservoirs in anti-spatter sprayers regularly, to ensure they have anti-spatter compound in them.

Similarly, if an operation is running a lubricator over an extended period, operators will need to refill the oil reservoir on the lubricator.
 

7 MIG Welding Mistakes and How to Avoid Them

MIG welding offers numerous benefits for productivity without sacrificing quality of the finished weld, but there are many factors that can interfere with successful MIG welding performance.

You can improve performance and results in your MIG welding applications — and save money through reduced consumable waste — by taking steps to avoid common mistakes related to the MIG gun and consumables.

Consider these common causes of poor performance in MIG welding and learn how to prevent them, for a positive impact on productivity and the bottom line.  

No. 1: Improper liner length

Cutting the welding liner the wrong length is a common issue in MIG welding. In many cases, it’s a matter of the liner being cut too short.

When the liner is the wrong length, it can cause poor wire feeding, an erratic arc and/or wire chatter. For conventional liners, use a liner gauge as a guide when trimming and installing the liner. Another option is to employ a consumable system designed for error-proof installation that eliminates incorrect liner trimming and requires no measuring. The welding liner loads through the MIG gun neck and is then locked in place at the front and back of the gun while also being concentrically aligned to the contact tip and the power pin. Once locked, the welding operator simply trims the liner flush with the power pin. In addition to accurate trimming, by locking the liner at both ends of the gun, it isn’t able to extend or contract. The result is a smooth wire-feeding path.

No. 2: Overheated consumables

When a MIG gun’s consumables become overheated, they can be the source of many problems. 

To prevent consumables from overheating, use the proper wire stickout, mind the gun’s duty cycle and employ the right contact-tip-to-work distance. Any steps that keep consumables cooler will help limit the amount of vibration in the gun and reduce issues with burnback.

While a wire stickout that is too long is not desirable, keep in mind that too short of a stickout can result in the nozzle and contact tip being too close to the weld pool causing them to overheat. This impacts productivity by causing burnbacks and wire sticks, and can significantly shorten consumable life.

Also, look for consumables with a tapered design, as this helps lock conductive parts together, resulting in less electrical resistance, lower heat and a longer life. Some consumable systems feature a contact tip that is buried in the gas diffuser, which helps reduce overheating. This design also allows the shielding gas flowing through the gun to cool the tail of the contact tip for added protection against overheating.

No. 3: A bad ground

Shortened life of the contact tip and other front-end consumables can also result if a solid ground isn’t in place when MIG welding.

Without a solid ground, the arc can become erratic and ultimately cause more heat buildup in the front of the gun. Any problem that creates more heat will also create more resistance and more wear — damaging the contact tip and other front-end consumables and possibly impacting weld quality.

To prevent these problems, place the ground cable as close to the workpiece as possible. If allowable, hook the ground cable on the weldment. If that is not feasible, hook it to a bench. But remember: The closer it is to the arc, the better.

No. 4: Improper voltage or wire feed speed

Setting the wrong voltage or the wrong wire feed speed can also cause an erratic arc.

Setting the voltage too high can create too much heat in the handle of the gun, which in turn can eventually wreak havoc on the contact tip.

When the wire feed speed is too fast, it can cause the wire to pile up instead of melting properly into the weld pool. This can also cause burnback or birdnesting. A wire feed speed that is too slow doesn’t feed the weld pool, so there is not proper penetration for a quality weld.

Always follow the manufacturer’s recommendations for the proper voltage and wire feed speed for the filler metal and thickness of the base material being welded.

No. 5: Poor cable management

Poor power cable management can lead to performance problems and cable damage.

To help prevent damage or other mistakes, don’t pull the welding machine around using the cable. When the gun is hot, everything is more pliable. Yanking or pulling on the cable can stretch the cable or the liner and even cause the conduit to pull away from the gas pin, which can result in shielding gas issues.

It’s also important to let the gun cool in a flat position, rather than draping or hanging the cable over a piece of plate or some other object. When a hot gun is draped or hung over something, it can bend the conduit. When the gun and consumables cool, they can be misshapen, leading to marginal shielding gas coverage.

Take care to lay the gun out properly to let it cool. Also, be sure to store the gun and cable properly when they aren’t being used to avoid damage that can occur if a cable is run over by a forklift or other heavy equipment.

No. 6: Selecting the wrong gun

A key step to prevent a MIG gun from overheating is to choose the right gun for the application. Be mindful of the requirements of the job and select a gun with enough duty cycle and amperage capacity.

If the application requires you to weld at 300 amps all day and you choose a 200-amp gun with a 30 or 40 percent duty cycle, this gun will not be up to the task. Exceeding the gun’s duty cycle leads to overheating — and doing this frequently will shorten the life of the gun.

In addition to choosing a MIG gun that has a high enough amperage rating and duty cycle rating for the job, you can also take breaks to let the gun and consumables cool to help avoid gun overheating.

A change in shielding gas can also help reduce the heat produced during welding. If you’re using an argon shielding gas, the higher the percentage of argon, the less cooling the shielding gas provides. However, keep in mind that many applications use argon shielding gas because it provides a cleaner process with much less spatter for reduced cleanup. So while reducing the argon can help the process run cooler, there are other tradeoffs that can impact productivity. 

No. 7: Drive roll issues

Using the wrong type of drive roll or setting improper drive roll tension can also be common mistakes causing of erratic or poor wire feeding in MIG welding. Consider the size and type of wire being used and match it to the correct drive roll. 

Because flux-cored wire is softer — due to the tubular design and flux inside — it requires using a knurled drive roll that has teeth that can grab the wire and help push it through. Knurled drive rolls typically should not be used with solid wire, since the teeth can cause shavings to break off of the wire, clogging the liner and creating resistance in wire feeding. Instead, use U-groove or V-groove drive rolls with solid wire.

Setting proper drive roll tension is another important step. Without proper tension, erratic feeding can cause burnback or other issues. To set the proper drive roll tension, start by releasing the drive rolls. Then increase the tension while feeding the wire into your gloved hand until the tension is one half-turn past wire slippage. Always keep the gun as straight as possible to avoid kinking in the cable that could lead to poor wire feeding.

Proper maintenance is also key

Avoiding common mistakes helps you get the best results in MIG welding. It is just as important to properly maintain the MIG gun and consumables, including the contact tip, nozzle and liner.

Whenever you change consumables, check that the gas holes in the nozzle are clean and that the seat that holds the contact tip isn’t filled with spatter or debris. A clogged contact tip or nozzle can cause overheating in the gun and handle.

Also check frequently that all connections are tight and as concentric as possible. Keeping the gun and cable as straight as possible during welding — and laying them flat to cool — makes for an effective and efficient MIG gun.

Follow these tips to minimize downtime, improve productivity and quality, and save money in your MIG welding operation.

Proper Ergonomics Improve Welding Productivity, Protect Welders

By Jack Kester, senior VP, Marsh Risk Consulting and Andy Monk, product manager, Bernard

What is ergonomics? While this term has several definitions, its practical meaning is “to adapt a task and work environment to a human.”

Despite what some think, the importance of ergonomics far surpasses comfort. A workplace environment or task that causes a welding operator to repetitively reach, move, grip or twist in an unnatural way — or even stay in a static posture for an extended time without proper rest — can do much more than become a literal pain in the neck. Over time, it can lead to repetitive stress injuries with life-long impacts that may even prevent the welding operator from working.

People are built with certain limitations, and when the design of work exceeds normal limitations, excessive wear and tear on the body occurs, accelerating damage that can lead to Work-Related Musculoskeletal Disorders (WMSDs) — injury to the muscles, tendons, ligaments, joints, nerves and/or spinal discs.

Although many welding operators may start with a dull pain that they dismiss as “just getting conditioned” or “tweaking something that will go away,” it can become more intense — and more expensive — and difficult to treat as time goes on. For example, early treatment for pain may require only ice, heat or some anti-inflammatories, and it might cost $200. However, waiting months or years to address the problem could result in invasive treatment and cost thousands of dollars. That is especially true with wrist and shoulder injuries that require surgery.

Ergonomics not only protects welding operators from injuries, but it can also improve the productivity and profitability of a welding operation. Stressful postures and motions tend to be inefficient. Lifting boxes from floor level or reaching outward beyond arm’s length, for example, takes extra time. These posture and motions repeated throughout the year by multiple employees can have a significant impact on earnings for the company.

By proactively reducing the risk of injury, companies can improve productivity, while also reducing employee absences and eliminating overtime pay for replacement workers who may not be as efficient or proficient. Eliminating stressful postures and motions can also help reduce employee turnover and training costs for replacing welding operators who quickly decide “this job isn’t for me.”

According to the Bureau of Labor statistics, WMSDs account for 29 percent of all lost workday injuries and for about 34 percent of all workers’ compensation claims — and they cost employers $20 billion each year in workers’ compensation.

Welding-related musculoskeletal disorders

Injuries ranging from mild and short-term to serious and chronic can result when the demands of a task do not naturally align with the capabilities of the welding operator. Most WMSDs develop when repetitive micro-traumas occur to the body over time.

WMSDs include strains or sprains, which can result in pain, decreased productivity, disability, medical treatment, financial stress and even a change in the quality of life for those affected. The most common symptoms among welding operators are shoulder pain, range of motion loss and reduced muscle strength. The most common injuries for welding operators include back and shoulder injuries, wrist injuries (such as tendinitis) and various knee joint disorders.

Today WMSDs are the fastest-growing disorder in the aging workforce because these illnesses have developed over time, before welding operations were as aware of them as they are today. As a result, there is the potential for an increase in claims costs in the coming 10 years as welding operators seek treatment.

The risk factors

There are three primary risk factors that increase the likelihood of developing WMSD injuries:

1) Highly repetitive tasks that keep an operator in a static posture for too long or use the same motion over and over, such as pulling a MIG gun trigger.

2) Tasks that require an operator to apply significant force or pressure, such as pushing, pulling or heavy lifting.

3) Poor or awkward postures, such as bent wrists or necks tilted backward.

In addition, environmental conditions such as extreme temperatures can also contribute to the development of WMSDs. Personal risk factors that increase the likelihood of incurring WMSDs include physical conditioning, pre-existing health problems, gender, age, work techniques and stressful hobbies.

Some common welding postures that are considered awkward and stressful include kneeling, squatting, torso twisting, leaning on a hard surface, holding the arms away from the body or above shoulder height for long periods of time, hunching or bending over, and looking upward too long.

In general, the best postures are those that are as close to neutral as possible — a natural position that the body would rest in if it were not doing anything.

Ergonomic solutions

The use of proven ergonomic principles can dramatically improve the way a welding operator performs a task, thereby reducing the exposure to risk factors and simultaneously increasing productivity. A simple work station adjustment or the use of different tools can make a big difference on an operator’s long-term health and wellbeing, as well as on the company’s bottom line.

For example, operators who weld with pistol grip tools, such as a welding gun, and use their finger to apply pressure for an extended length of time can develop “trigger finger.” This problem can be easily resolved by using a welding gun with a locking trigger.

Welding operators should position their work between the waist and shoulders, whenever possible, to ensure they are working in a close to a neutral posture. Achieving this posture may mean using work stools or height-adjustable chairs, as well as lifting tables and rotational clamps or other material-positioning equipment. All these solutions can reduce awkward postures and allow employees to work in more neutral positions.

Welding guns with rear swivels on the power cable can help reduce the stress of repetitive motions. Different combinations of handle angles, neck angles and neck lengths can also keep an operator’s wrists in a neutral position. In some cases, a welding gun with a rotatable neck can help the welding operator more easily reach a joint, with less strain on the body. Manipulators, lighter-weight welding guns, lighter power cables with low stiffness and cable supporting balancers can also be invaluable.

Remember, the working height of a welding operator’s hands should typically be at elbow height or slightly below.

The engineering controls described above are effective because they reduce or eliminate risk factors in the workplace. Administrative control measures, such as job rotation and stretching programs, can also be used to reduce the exposure time for welding operators or at least prepare their bodies for the work-related stress.

The keys to an effective ergonomics program

An effective and sustainable ergonomics process provides a structured approach to reducing risk in the workplace and preventing WMDs over the long-term. It typically includes:

1) A formal ergonomics risk assessment process to identify and prioritize high- risk work.

2) A structured task analysis process to define the causes of the risk factors, leading to the development of practical engineering controls.

3) An action plan developed by management stakeholders to set expectations and allocate resources for ergonomics in the workplace.

4) An ergonomics team trained to implement the ergonomics process and empowered to implement the action plan.

5) A formal process for developing, implementing and validating ergonomics solutions for high-risk tasks.

6) Ergonomics training for management, supervisors, the ergonomics team and other production staff members.

Once an ergonomics solution has been implemented, it is important to provide frequent reinforcement to the welding operators to ensure that the solution is utilized effectively. It can be difficult, initially, for a welding operator to get comfortable with new work practices if the job has been done a specific way for years. Therefore, it is important for welding operators to use any new welding gun and implement new best practices for at least 30 days. At that point, they can provide valid feedback on how well the new equipment or practices work for them. After all, gaining the benefits of proper ergonomics is only possible if they are used and the welding operator also sees the results.

In the end, the goal is to secure the safety of the welding operator, which requires an active commitment on the part of both the individual and management. Gaining the benefit of ergonomics is a team effort — one that ultimately provides a comfortable work environment, leads to a more productive and profitable welding operation, and provides for the long-term health of the welding operator.

Tips to Optimize the Robotic Weld Cell

Companies invest in robotic welding systems to improve productivity and gain efficiencies in their operation. But if the weld cell layout is not optimized, it can negatively impact those goals — along with the quality of the completed welds.

Poor cell layout can create a bottleneck in the process or result in parts not being properly welded —problems that cost time and money in the long term. 

When considering proper layout for a robotic weld cell — whether it’s a pre-engineered cell or a custom cell —gun and consumable selection, robot reach, parts flow in and out of the cell, and weld sequencing are all important.

Pre-engineered or custom welding cell?

Proper weld cell layout is important for both pre-engineered robotic welding systems or a custom-designed system. Determining which option is right hinges on several factors.

A pre-engineered robotic welding cell is designed for welding specific parts in a certain size range. Pre-engineered cells offer benefits for easy and fast installation and a much lower first cost, but they do have their limitations regarding the type and size of parts that can be welded. Part size is often the key determining factor when choosing between the two systems. 

If there isn’t a pre-engineered weld cell available to fit the parts — perhaps there is a reach or weight capacity issue — then a custom robotic weld cell is the better option. Custom cells have a higher initial cost and typically a longer lead time for design and installation, but the upside is they can be customized to meet specific needs.

When installing either type of robotic weld cell, the system integrator should be involved in planning and testing to ensure cell layout is optimized for the application.

Choosing the right gun and nozzle 

Having the right gun is a critical factor that can help reduce or eliminate the sources of common problems in the weld cell. Gun choice should not be an afterthought in robotic welding applications. The gun must have proper access and be able to maneuver around fixturing in the weld cell. Different choices in gun types and in consumables can help in achieving this.

Robotic welding systems are available in two styles: through-arm or conventional. Through-arm systems are gaining popularity, and most through-arm robots allow for mounting either type of gun — providing more options and flexibility depending upon the needs of the application.

As the name suggests, the power cable assembly of a through-arm MIG gun runs through the arm of the robot as opposed to over the top of it like in a conventional gun. Because of this design, the through-arm gun style is often more durable, since the power cable is protected. However, because conventional guns can be used on either type of system — a through-arm or a conventional robot — they can sometimes offer greater flexibility, and can be used with more robot makes and models. Consider which type of gun provides the best access to the welds when making the selection.

With conventional robotic welding systems especially, proper cable management is important. Once the hardware is installed and the system is set up — but before full production begins — be sure to do a test run or two through the welding sequence to determine how the gun cable moves and if it gets caught on tooling.

Another choice in selecting a gun is air-cooled versus water-cooled. This essentially comes down to the required duty cycle. The base material thickness, weld length and wire size all help determine the necessary duty cycle. Water-cooled guns are typically used in manufacturing heavy equipment and in the case of long cycle times and large wire diameters.

Once the system type and gun is chosen, it’s all about proper fit and function of the gun. It’s critical to ensure the robot arm can access all the welds — ideally in one position with one neck if possible. If not, different neck sizes, lengths and angles — and even custom necks — as well as different consumables or mounting arms can be used to improve weld access.

The choice of nozzle is another important consideration, since it can greatly hinder or improve access to the weld in a robotic cell. If a standard nozzle is not providing the necessary access, consider making a change. Nozzles are available in varying diameters, lengths and tapers to improve joint access.

While many companies like to choose a nozzle with the smallest outside diameter available, it may be necessary to size the nozzle up to avoid spatter buildup and loss of shielding gas coverage. A nozzle with a 5/8-inch bore or larger is recommended because it allows the most access. 

Key considerations for proper layout

Choosing the right gun is tied closely to proper weld cell layout — since different sizes and lengths of guns and nozzles can improve or hinder reach to the welds. However, there are also many other factors involved in proper weld cell layout. Think of weld cell layout as the footprint of the entire process. Some important issues to keep in mind:

• Robot reach: It’s critical to match the size of the part being welded with the reach of the robot. A small robot welding on a very large part won’t work well, and a large robot shouldn’t be welding on a very small part. The robot must have the capability and position to reach all the areas on the part that require welding. If there is a weld on the edge of the reach envelope, for example, it might force a company to sacrifice optimal gun angle or work angle to reach that weld. This can impact weld quality, resulting in potential rework and added costs. It can also lead to premature gun or cable failure, if the robot is constantly trying to access a weld that isn’t accessible in the configuration. Many robotic welding cells mount the robot on a riser for better access to the part. Pay attention to proper riser height to optimize the access of the arm to the welds.
• Size and weight capacity: To ensure proper operation, the size and weight capacity of the positioners in the robotic weld cell must factor in not only the weight of the part, but also the weight of the tooling. Undersizing the positioner or weight capacity of the cell is a common mistake. To address this, design the cell for the heaviest part to be welded. Consider the project scope to ensure the welding system always has the capacity to handle the heaviest part in the operation.
• Material flow: The flow of material in and out of the weld cell, in addition to the sequencing of the welding process, are key in determining the right layout and positioning. Understand the material flow to the robot, how the material will be presented to the robot, and then how that welded component will be removed from the cell and moved to the next step in the operation. The weld sequence should be planned in advance, to ensure the robot can reach all the welds with the gun configuration being used.
• Test it with modeling: Software programs that allow virtual modeling or simulation of the weld cell provide the ability to test the many factors involved in proper robotic weld cell layout — from gun and nozzle choice to material flow. Take the time to simulate the weld cell layout and welding process during development. This helps determine which product and positions are needed — and helps avoid issues that could arise later once the weld cell is installed and running. In modeling, consider the components, gun, positioner, tooling, arm movements and the part itself. All these pieces must fit together and work properly to ensure the desired results. The beauty of offline programming and 3D modeling is that these components and factors can be tested virtually, without wasting materials or consumables. It’s better to prepare and prevent problems — rather than face repairs later.

The right choices enhance productivity and quality

Weld cell layout and the chosen components that fit inside have a significant impact on productivity, efficiency and quality of the finished welds. Weld cell layout that is not optimized can even harm the tooling or consumables, and result in increased time and money spent on maintenance and repair.

Protect the robotic weld cell investment by taking the time at the start of the process to test proper cell layout and equipment — to help ensure the end results and productivity gains being sought.