Robotic Welding Programming and Operation

Three days on KAIERDA robotic welding cells: teach pendant programming, torch angles, weave patterns, parameter sets, fixturing and recovering from a failed weld.

What You Will Be Able to Do

• Move the robot safely in joint, world and tool coordinates
• Teach a weld path with correct torch angle, approach and retract points
• Set and store welding parameters for a joint, including weave and dwell
• Design and use a fixture that puts the part in the same place every time
• Diagnose a failed weld and recover the program without starting over

Who Should Attend

• Welders and technicians taking over a robot cell
• Production engineers planning automation
• Maintenance staff supporting the cell

Course Outline

• Day 1 Safety, coordinates and first motion6 hours
  • Cell safety: fencing, light curtains, enabling device, speed limits in teach mode
  • Robot anatomy: axes, home position, singularities and soft limits
  • Joint, world and tool coordinate systems, and when to use each
  • The teach pendant: jogging, saving points, editing a program
  • First program: a straight line weld on a test coupon
• Day 2 Welding parameters and weave6 hours
  • Digital pulse MIG/MAG: synergic lines, wire feed speed, arc length and inductance
  • Torch angle, work angle, travel angle and stick-out
  • Weave patterns for fillet and butt joints, and when weaving hurts
  • Arc start and crater fill: the two places most welds fail
  • Building a parameter table for your own joints
• Day 3 Fixtures, production and recovery6 hours
  • Fixture design rules: datum, clamping, heat expansion and access for the torch
  • Positioners and coordinated motion for out-of-position welds
  • Cycle time: where seconds are actually lost
  • Common faults: porosity, undercut, burn-through, wire stubbing, nozzle spatter
  • Recovering a program after a collision or a power cut, and re-teaching one point

Machines and Tools You Will Train On

KAIERDA welding robots with digital pulse MIG/MAG sources, positioners, fixtures and test assemblies.

Prerequisites

Manual welding experience (MIG or TIG). No programming background needed.