Robotic MIG / MAG Welding

In a gas metal arc welding system, the “power source” is the heart of the system. In the welding torch connected to the robot, it provides the necessary power for the wire to become melted. Thus, metal parts are welded to be joined together.

The operator sets, saves, monitors and changes the required welding parameters through this interface whenever they want. On the latest Fronius tps / i welding machines, this interface has a digital touchscreen display, is robust and functional. From this interface, it is possible to control all variables (robot zigzag parameters, robot speed, etc.) that affect robotic welding performance and quality.

It is a high speed universal (EtherCAT etc.) communication infrastructure that enables the communication between the Control System of the Robot and the Power and Control Unit of the Welding Machine. When this special communication infrastructure is not available; While the robot is an empty manipulator without a process tool, the welding machine is a manual machine that allows welding only by hand. Thanks to this communication infrastructure, the robot and welding machine can operate as a single system with plug-and-play convenience. In both elements, all functions are transformed into a single body with unlimited and trouble-free “robotic welding” features and characteristics. With this universal communication structure, all brand robots can communicate with all brand welding machines.

In welding processes above 200A, a water-cooled welding system has become a more preferred option. Air-cooled systems are generally preferred for standard welding processes below 200A.

However, considering the torch mechanization in the system, the life of the whole installation and hose packages, as well as the consumption consumption and welding quality, water-cooled systems seem advantageous in the long term. For water cooling, the waterline is installed as a separate closed loop line in the hose package of the welding system and runs up to the torch attached to the final flange of the robot and capillary cools all elements of the torch mechanization

Our solutions include Wire Feeding Units in 3 different configurations. 5A – Wire Feed Unit Mounted On Robot 4th Axis Back. 5B- Wire Feed Unit Mounted on Robot 3rd Arm. 5C- Wire Feed Unit Mounted on Wire Bar. The secret of flawless, uninterrupted, trouble-free welding and creating customers who do not need service with years of experience; in detailed configuration, characteristic accuracy and process fineness. Therefore, wire feeding units are offered in 3 different configurations and types depending on the application. The Wire Feed Unit feeds the welding wire to the torch by pulling the wire from the drum or coil package wire package for welding and ensuring correct force controls. Requires reel adjustment or change according to the diameter of the welding wire. It has a characteristic suitable for the voltage and current capacity of the power supply. It automatically adapts to the speed in variable time and feeds the wire. It contains an accelerated force sensor and a controller, thus preventing ruptures. It provides powerfully real-time pushing of the wire to the torch according to the specified characteristic. Below is a description of the 3 different wire feed combinations.

A – PowerDrive System. Only one wire feeder unit called WF 25i RD is used. This unit is placed directly behind the robot, providing a safe, strong and stable wire feed quality. This dynamic wire transmission enables the PMC Mix Drive process, which creates highlights, especially in the aluminum field.

B – PushPull System. It is equipped with two perfectly synchronized wirefeeders that provide the highest precision wire feeding. It is a meticulous wire feed set for high process stability, especially for long wire feeds and soft filler materials (aluminum etc.). No breaks, blockages occur and provide uninterrupted comfort of doing business.

C – Push System. It is equipped with two perfectly synchronized wirefeeders that provide the highest precision wire feeding. It is a meticulous set of wire feeds for high process stability, especially for long wire feeds and soft filler materials (aluminum etc.). No breaks, blockages occur and provide uninterrupted comfort of doing business.

It mounts the Wire Feed Unit safely to the robot and provides insulation.

The hose package contains the communication bus for the wire feeder, the positive or negative supply for the self-shielded wire, the shielding gas hose and the water / air cooler lines.

During the use of the robot, it disconnects the torch mechanically when the torch connected to the robot hits something, it prevents the torch from being warped, damaged, losing its direction and plane and breaking. It also stops the robot at high speeds.

It mounts the Wire Feed Unit safely to the robot and provides insulation.

The data, air, gas, water and wire line, each isolated from each other, are combined in a single hose set and goes directly from the wire feeder to the torch. When it reaches the torch, all lines are combined with the interfaces in the separate torch and perfect integration is achieved.

It is the most important part defining the torch for the welding process.

Welding wires are packaged by the manufacturers in the form of spools or drums. The spool type welding wire supplies are placed directly in this chamber and the end of the welding wire is attached to the wire feeder.

It is the welding wire pipe installed between the Spool Type Welding Wire Hopper and the Wire Feed Unit and acts as a safe physical channel that enables the wire to be transferred to the wire drive.

It consists of wire cutting, Mechanical Torch Cleaning (2 separate types, inside and outside nozzle) and Spraying System. It is the complete solution for automatic maintenance of the torch. Provides precise and effective clean for almost all robot welding torches. In the first stage, the robot is automatically positioned on the wire cutting unit, the robot automatically drives a certain amount of wire. Since the direction of the welding wire may be distorted and clumping may have occurred at the end, the welding wire is cut at one point at the end of the robot and the negative aspects of the wire are eliminated. In the 2nd stage, the robot is automatically positioned in the mechanical torch cleaning unit. The unit grasps the torch nozzle firmly and enters the nozzle with a kind of nozzle milling cutter and cleans all the burrs formed on the inner wall of the nozzle by milling. As the 3rd step, the Robot moves to the appropriate position at the spraying point and is automatically applied to the nozzle by means of liquid spraying known as Anti Spatter (TMS-VI). Thanks to this liquid, adhesion of spatter burrs to the nozzle during welding is reduced and the service life of the torch is extended, the process quality of the weld is positively affected.

Welding wires are packaged by the manufacturers in reel or drum type. It can be ordered from manufacturers in cardboard boxes of 250 to 500 kg. Wire drum systems ensure efficient MIG / MAG welding by preventing downtime caused by reel change, especially in robotic applications.