I am considering purchasing a Fornius robotatic CMT Welding Process. My published Customers require I comply with ASME Section IX. How does this process meet the ASME Section IX requirements?
Josh Williamson from Fronius - Robotics Segment Manager
williamson [dot] joshua [at] fronius.com (877) 376-6487
John,
CMT is a GMAW process (with advanced control). You would need to qualify the welds just like any other robotic welds.
ASME code can be sometimes difficult to interpret. Please contact Mike Ludwig directly to discuss this topic in more detail.
Best Regards,
Joshua Williamson
Mike Ludwig
Ludwig.Mike@fronius.com
Fronius USA
810-844-3456
Kevin Summers from Miller Welding Automation, An ITW Company - Operations Manager
kevin [dot] summers [at] millerwelds.com 630-315-9088
John,
Josh Williamson is correct. Each weld process has to be qualified on your material and joint.
Miller Welding Automation also has this type of advanced GMAW process. In our equipment it is called Active Wire Process. AWP. Our application team has experience welding pipe robotically and we have a dedicated application lab in Chicago to run sample parts for customer. Let us know how we can help
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What is the better option between OTC Robots versus Universal robotics? I will be using them for welding small parts.
Jason Jamiel from KC Robotics, Inc. - Service Manager & Senior Applications Engineer
jjamiel [at] kcrobotics [dot] com (513) 860-4442
Hi there! i worked for OTC/Daihen for 13 years. The primary reason you would want to use the Otc robot, is Otc's software platform is designed around their welders, so the functionality of the machine is far greater than other robots. What model are you using? (robot and welder type). Also, are you pulse or short arc welding? shoot me a line and I can help you with ANY questions you may have! Take care.
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
Universal Robotics is not necessarily designed for welding. You can also consider Yaskawa Motoman who has an office in India. Please contact: Vikas.Marwah@yaskawa.in
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I have a question about programming a robotic welder. I ran a program and the robot was done welding; I received an error message that said wrong welder and didn't continue. I need assistance in resolving this problem.
Mark Oxlade from ABB Inc. - Maket Development Manager - Welding & Cutting
mark [dot] x.oxlade [at] us.abb.com (248) 391-9000
Hi Kory, you need to specify which robot and power source combination to get the assistance you need. ABB operates a 24/365 helpline (800-HELP-365) direct to technicians. The ABB robot does not have to been purchased form us to qualify for the free assistance. I trust you get up and running soon.
Jason Jamiel from KC Robotics, Inc. - Service Manager & Senior Applications Engineer
jjamiel [at] kcrobotics [dot] com (513) 860-4442
Hey there, are you running a tandem welder set up? Like an OTC/Daihen system that can run a mig tig set up, you have to select the right welder during the arc start statement. Or are you running two robots on one controller?
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
The Motoman robot has a "wrong welder" alarm, but it normally occurs at the start when the power source condition file is missing some data. Yaskawa Motoman has a service hotline; 937-847-3200.
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Is there an industry standard for changing weld wire on a robot?
Kevin Summers from Miller Welding Automation, An ITW Company - Operations Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3876
John,
Your question is a little vague. I am not sure I will answer the question correctly so please contact me directly for more follow up.
If you are changing brands, there is no standard other than what you may have qualified to. If you qualified the welds with a ER70S-6, then you should stay with that designation.
If you are changing wire diameter, you simply have to match your amps and volts to what you qualified the part with. There is no standard to say do this or that when changing from 035 to 045.
If you are changing from solid wire to metal core, for example, you will need to qualify, through inspection, the weld quality to ensure it matches your procedures.
Miller Welding Automation is located right here in Carol Stream, IL. If you have some part samples you want us to run, send them in and we will help you.
Jason Jamiel from KC Robotics, Inc. - Service Manager & Senior Applications Engineer
jjamiel [at] kcrobotics [dot] com (513) 860-4442
Hey there, what exactlly are you looking for here? inter connecting weld spools for constant production? if you would like to email me some details I will help you out as much as I can!
Wes Doneth from Fronius - Tech Support Manager
doneth [dot] wesley [at] fronius.com (877) 376-6487
Rule of thumb change out time is 15 minutes
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I have a Weld issue with our OTC Ax (2005 Model) using a DP400 for power supply, we are welding Pulleys using pulse welding, I do not know a whole lot about pulse welding however, it is like trial and error. The problem we are having is when using pulse welding and he set Parameters like 24.5V/465/25 the weld sounds NICE but the appearance is low and looks like alot of undercut. the Placement of the wire is in the right spot. (right in the crack) when I go into the next screen where slop down is and all the other settings I don’t really know what I’m doing so I’m guessing and sometimes it works. I guess what I’m asking is like a cheat sheet for Parameters or an explanation about pulse welding like slope down? Or a website for better understand of pulse welding
Thanks
Jason Jamiel from KC Robotics, Inc. - Service Manager & Senior Applications Engineer
jjamiel [at] kcrobotics [dot] com (513) 860-4442
Hey there, there was a glitch when i was responding to your question so I'm not sure if it went through. email me at jjamiel@kcrobotics.com and I'll fix your issue for you..
Wes Doneth from Fronius - Tech Support Manager
doneth [dot] wesley [at] fronius.com (877) 376-6487
Brandon,
If you were not able to resolve your issue with an OTC machine or unable to get support we can discuss the advantages of Fronius equipment.
Best Regards,
Wes
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I know how to set up a job that has already been programmed, but I need to know how program an arc welding robot to perform a new job. The model we have is made by Panisonic.
Kevin Summers from Miller Welding Automation, An ITW Company - Operations Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Shawann,
If you have training type questions on the Panasonic robot, you can now contact Miller Welding Automation for support.
James Manning is our trainer and can help you with all kinds of questions.
james.manning@millerwelds.com
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My Panasonic welding robot (vr2 series) wire feed motor fell down from robot top, after fixed CODE : A3510 IPM ERROR coming. Checked control cable and feed motor and all still problems not solved. Please give solutions for this.
Paul Visscher from JR Automation Technologies LLC - Robotics
(616) 820-3380
Check the 5 amp fuse that is located by the DC power supply in the welder. Also, double check your cables and connections for damage. We hope that this helps solve your problem, as we (Epoch Robotics) are Panasonic robot authorized in integration and repair.
Kevin Summers from Miller Welding Automation, An ITW Company - Product Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Please contact Miller Welding Automation service team for more support.
mwaservice@millerwelds.com
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I am encountering an Intermittent Arc start fault on my OTC V6 robot. This robot has been welding fine for several years, but just started to develop a Fault .The robot will start to stubbing and stop welding (Error ARC START). I had the welder tested, and I have run the program on its own. They both seem to work fine on their own. I had OTC and welder Tech perform separate tests & can not find the problem as it works fine when they are around. Then they leave & the fault develops again. Can somebody please steer me in the right direction know what I should be looking for? Oh I`m running 110A @ 19vdc and using co² Gas if this helps.
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
Check your weld grounds as these can degrade over time. You can feel by connection points to see if the cables get hot indicating a poor connection.
Also check the material condition at the start. You might be getting occasional mis-located parts or oil deposits causing the arc faults.
Lastly, note other changes which may have coincided with the start of fault occurances; new wire type, gas change, different contact tips. Someone may have implemented a cost savings measure which inadvertantly caused a welding issue.
Jason Jamiel from KC Robotics, Inc. - Service Manager & Senior Applications Engineer
jjamiel [at] kcrobotics [dot] com (513) 860-4442
Hey there, I worked for otc for 12 years and was their senior tech/applications engineer. let me know if you still need some advice on your system. Are you running an ex or ax controller? turbo pulse welder or dp400,dm350 etc. shoot me an email and id be glad to help you
jjamiel@kcrobotics.com
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Please let me konw if somebody has pulse auto welding parametersfor pipe line.
I have an SK6 with an MRC2 controller. I am thinking of putting a Miiler Auto Invision II on it. We're welding round tubing 065 erw. Do you think this machine would be suitable for this welding application with minimum or no splatter? Or is there something else you would recommend?
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
The AutoInvison II is an older welder. I would suggest using a newer Miller AutoAxcess power source which has better arc characteristics. They make an AutoAxcess 300 with 350 amp max amperage that would be suitable for your application. It has an analog interface which is compatible with the MRC controller. We sell an interface cable between the MRC and AA300 (137309-11). You can contact Motoman customer service for more information at 937-847-3200 or techsupport@motoman.com.
Wes Doneth from Fronius - Tech Support Manager
doneth [dot] wesley [at] fronius.com (877) 376-6487
Kelly,
If you haven't already found a solution check out CMT from Fronius.
www.fronius.com
CMT is spatter free GMAW welding
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We are aluminium mobile scaffolding manufacturing company placed in Abu Dhabi, U.A.E. we purchased motoman UP20-6X RC Robot from USA. we want professional operator who is having troubleshooting skill if you have please refer us.
Mobile: 00971 55 8873740
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
You can call our customer service hotline in US (Eastern time) at 937-847-3200 and we will try to answer questions for you. You can also email questions to techsupport@motoman.com.
Support for UAE is covered by our European office which is headquartered in Germany. You can contact them via website to try and obtain a local service contact.
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For built up sections can we make one side weld: automatic?
Kevin Summers from Miller Welding Automation, An ITW Company - Operations Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Mr. Kamaal,
Whether or not you can make one sided welds depends on the penetration and performance criteria established during your procedure specification process. We would need more information to answer this question more fully.
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Hi guys, my question is a little different. I purchased two Miller Auto Invision 2 welders from a plant that was closing. I am keeping 1 as a Robot welder and would like to use the second as a regular manual feed Mig Welder as it will give me a longer duty cycle and more output than our shop mig as I would like to use .052 Wire. What is available for me to make this work, what advice could you give me and where can i get it from you guys? Thank you, Kimble Kirschner, JKS Custom, London Ontario Canada. P.S. Thanks for offering such a great resource in your site.
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com
You can get information from Miller Electric on a feeder system that will allow you semi-automatic control of you AutoInvision. You can send an inquiry to their automation groups website: http://www.millerwelds.com/AMS/aeforms/.
Kevin Summers from Miller Welding Automation, An ITW Company - Business Development Manager-Automation
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Kimble,
Great question. Contact us directly here at Miller Electric and our welding engineers and service techs can help you out.
Miller Electric Mfg. Co.
Application and Service Hotline 1-866-931-9733
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I am looking for automation in my pipe shop. We fabricate different kinds (CS, SS, AS) of different standards. Can you suggest robotic arms capable of manufacturing these pipes?
Mark Oxlade from ABB Inc. - Welding Manager Eastern Region
mark [dot] x.oxlade [at] us.abb.com
The welding of pipe in the construction industry provides it own unique set of challenges with low volume and high diversity. The application of ABB’s robotic Studio addresses these issues head-on. If you would like to provide me with some more data I will assist in coordinating a local review of your arc welding project. Ta MO….
Kevin Summers from Miller Welding Automation, An ITW Company - Business Development Manager-Automation
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Mr. Mahesh Pingali,
Robotic welding of pipe is very possible. The robot is able either hold a fixed position while the pipe rotates for welding flanges or joining sections. The robot can be programmed to weld saddle joints or other complicated connections. It is important to understand the difficulty in welding overhead with a robot so some kind of positioner/manipulator is recommended as well. Motoman makes a very good arm, positioners and they also have the technical staff to help realize such a project.
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I'm a component supplier to 2 wheeler industry in India and am looking for the most effective Arc Welding robot in terms of performance, speed and reliability. Can you suggest to me the name of a supplier from whom I can buy the welding robot? As of today Motoman, ABB , FANUC, OTC, KUKA and Panasonic have offices in India and are active.
Kevin Summers from Miller Welding Automation, An ITW Company - Business Development Manager-Automation
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Please contact me directly and we can discuss your options.
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com
Yaskawa supports sales of Motoman robots with offices in India. If you email me directly, I will forward to the manager of Indian office.
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I need to weld 0.7mm gauge steel. I have an auto axcess 300 with RMD optional. What transfer mode should I use? I have both 0.9mm and 0.6mm wire.
Kevin Summers from Miller Welding Automation, An ITW Company - Business Development Manager-Automation
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Sergio,
You will want to use the RMD transfer method. You will find there is a standard 0.9mm program built into the Axcess. The 0.7mm material is very thin. You may want to use the 0.6mm wire. We have a custom program for RMD and 0.6mm wire. If you will contact me via email, I can send the program to you and you can download it into the Axcess machine.
Wes Doneth from Fronius - Tech Support Manager
doneth [dot] wesley [at] fronius.com
Sergio,
I can't assist you with the Miller equipmment but if you are not able to acheive your desired results please contact me and I can put you in touch with Fronius representative in South America. Our CMT process works excellent for the type of application you are working on.
Regards,
Wes
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We are wondering whether welding parameters are different for MIG welding and robotic welding. We are using 1.6MM solid wire with CO2 gas for welding steel of thickness varying from 20 to 80MM .
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com
If you have a qualified manual welding procedure, then you can normally use those parameters in the robot. This can often save you from requalifying the procedure if the robot is welding within the essential variables.
The robot is normally capable of welding faster than manual welders with different process settings. This may require you to qualify the procedure with the robot settings.
Kevin Summers from Miller Welding Automation, An ITW Company - Business Development Manager-Automation
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Mr. VINAYAGAM VENKATESAN,
Welding is welding. The parameters are set by the material thickness, the shielding gas used, the wire type and diameter, and the travel speed. Robotic arc welding is typically at a faster travel speed than manual welding. On heavy plate, with large bead sizes or heavy deposition, the speed is dictated by bead size. When we convert customers from manual welding to robotic welding we always start them at the same parameters they were using and then work up 5-10-15-20% from there to find the optimum conditions.
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I have a big robotic aluminum welding project coming up and would like some feed back on what type of power source to use? Lincoln, Miller, or Fronius? I am looking at welding 1/2" plate to 1/2" aluminum angle iron using a 1/4" fillet weld. Any suggestions
Stefan Mayr from Fronius - Robotics/Integration
mayr [dot] stefan [at] fronius.com
Kirk,
Fronius is known as the Aluminum welding company and most integrators make Fronius the first choice on aluminum applications. For ½” plate to ½” Aluminum angle either a 0.045” wire or 1/16” wire could be used. The 1/16” wire will help to keep travel speeds high and with the higher current density gained from 1/16” penetration and side wall fusion should not be an issue. If this is a military project the base material is likely a 5xxx with the filler metal being either ER5556 or ER5183. These wires have a higher mag content. With a low arc pressure the weld can easily become consumed with porosity. Fronius has optimized and field proven programs to give the highest quality and repeatability.
Best regards
Stefan Mayr
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com 937-847-3216
Aluminum of the thicknesses you describe are able to be welded with any of the brand power sources you listed. You have a Miller AutoAxcess, which is capable of welding aluminum, on a Motoman robot. The larger 1/16 diameter electrode would improve speeds as Fronius indicated. It also reduces feeding issues allowing a push only feeder to be used successfully. It should be possible to use your existing robot system by changing to aluminum torch consumables and feedrolls.
Kevin Summers from Miller Welding Automation, An ITW Company - Business Development Manager-Automation
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Kirk,
Mr. Anderson is correct. The large fillet you are looking to make allows you to use large diameter wire. With large diameter wire, you could use standard feed motors. Push Pull is still available with the Auto Axcess if you desire but in most cases, the short gun length and the large wire diameter make it possible to weld aluminum using your existing equipment. There are many standard aluminum programs built into the Auto Axcess. I would like to have our local welding engineer contact you directly.
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I have spatter issues, Could you recommend some schedule settings to maybe help reduce some, if not all, of this issue? I have a Motoman SK-16 with a Miller Autoinvision welder and a K-10 with a Autoinvision II welder. I am welding 14 gauge C1020 EWT tubing with Hobart Trimark Vantage .045 wire, with a gas mixture of 92% argon and 8% co2. All of the welds are in very close tight quarters of eachother. Currently I am running 18v 155a 60cmm.
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com
Mark,
I think you can stand to go another 0.5 -1.0 volt lower on voltage. Plan B is to try pulse welding with your AutoInvision. You are using metal cored wire and it will melt at a lower average pulse current that solid wire. Your older AutoInvision may or may not have a pulse schedule for cored wire. Many times you can use a pulse schedule for the next smaller solid wire, i.e. use 0.035 solid pulse schedule for your 0.045 metal cored wire.
You can contact the Motoman tech support line for more assistance at 937-847-6200 or techsupport@motoman.com. You can also contact Hobart Brothers, www.hobartbrothers.com, or Miller Electric at www.millerwelds.com/ams/home for the advanced manufacturing division.
Kevin Summers from Miller Welding Automation, An ITW Company - Manager-Automation and Customer Support
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Mark,
It sounds like you are MIG welding based on the 18V and 155 amps weld condition.
Pulse welding would help to elimnate the spatter but there is a concern that GMAW-P will be too hot for the 14 ga tubes you are welding.
Mr Anderson from Motoman gave some good suggestions. Sometimes moving to a smaller diameter wire and in your case you would have to move to a solid wire in the 035 class, helps control the spatter in low voltage MIG welding.
The AutoInvision and AutoInvision II are older power supplies and do not offer the same level of control and process choices available in the Auto Axcess today. The Auto Axcess offers and optional process called RMD. This is a short circuit process that elimnates spatter.
Please contact our application support hotline 1-888-931-9733 or visit www.millerwelds.com/AMS and click on the Auto Axcess video to see a demonstration of RMD.
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I just bid a sizable project involving 1" sq. tubing aluminum frames using 6061 and 4043 filler. The process must be Tig. I have an ABB 1400 robot cell with a 500c Manipulator. I am looking for a company who could help advise on jigging and also outfitting the robot with the best aluminum tig welder available due to the precise nature of the job. Also, I would be interested in hiring an expert tech to come out for a week at a time to help with setup. - possibly 3 to 6 weeks total for the different segments of the job.
Stefan Mayr from Fronius - Robotics/Integration
mayr [dot] stefan [at] fronius.com
Kendall,
For the welding equipment I suggest due to our experience in aluminum welding -> Fronius USA.
www.fronius.com
We offer equipment for TIG fusion, cold and hot wire, Plasma, MIG, TWIN, Laser Hybrid, RSW,..
Best regards
Stefan Mayr
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com
I suggest you contact Fronius in Brighton, MI. They have packaged robotic TIG systems including wire feeders. I question the mandate for TIG. The GMAW process has progressed significantly to the point where cosmetics will rival GTAW welds. From a production standpoint, you will be far more productive if you can use the GMAW process. Fronius has a Cold Metal Transfer (CMT) process which is applicable to thin aluminum.
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We are looking for a track type robotic welding system that can weld lap joints on pipe inside and out, 3/8 to 1/2 inch thick mild steel, four to eight feet in diamenter. We are open to any suggestons and help. Thank you.
Troy Sather from Ellison Technologies Automation - Integration Manager
tsather [at] ellisontechnologies [dot] com 402-650-5242
Brian,
We specialize in custom welding cells like what you are talking about. We also build Tracks for our applications and we sell them to other integrators.
Please contact Jeremy Walter for assistance:
402-650-5241
jwalter@ellisontechnologies.com
Thank you,
Troy Sather
Chuck Boyer from Wolf Robotics & Rimrock Corp. - Marketing Coordinator
chuck [dot] boyer [at] wolfrobotics.com
Brian,
We have extensive experience in custom engineered robotic welding systems and can supply several examples of solutions we have provided for over 30 years. Please contact our regional manager Chris Norris at 970-219-5806 or email him at chris.norris@wolfrobotics.com to discuss specifics. You can also visit our website www.wolfrobotics.com for more information. Best Regards, Chuck Boyer
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com
Motoman has supplied multiple robot systems for irrigation piping on 6-12 in dia. pipe. This included multi-process plasma cutting, handling, and welding of pipe nipples. We have processed heavier piping for oil and gas industries. We have an office in Toronto that services Canada.
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If I want to weld SS 316L to Stelleite 6 material which electrode or filler wire I should use???
Kevin Summers from Miller Welding Automation, An ITW Company - Business Development Manager-Automation
kevin [dot] summers [at] millerwelds.com (920) 954-3876
ASM and other authors recommend using AWS ERNiCr-3 and AWS ERNiCrFe-6 and AWS ERNiCrMo-3 when welding to softer materials.
Other resources:
http://www.hightempmetals.com/techdata/hitemp6Bdata.php
http://www.drmsmetals.com/data/weld/range.html
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I need to weld in puls MAG Fe using Motoman robot whit Comarc but the weld is snaking. I had checked the phase compens. value, U/D, L/R and it is correct. Do I have to change the weaving and how (increase or decrease FREQUENCY)?
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com
If the weld is "snaking" back and forth in the joint, then you need to change the correction quantity and make it lower. This is like a gain to make the robot respond more to corrections. The correction quantity is set by parameter, default is 0.1 mm.
I suggest you follow up with your local Motoman support agent at info@motoman.de. You can contact Motoman, Inc with more detailed information on the model of controller, etc. at techsupport@motoman.com.
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I'm welding four 1 3/8"x .065 tubes to a 2 1/2" x .065 tube in line about 2" apart. The material is 409 stainless. The process is GTAW. My robot is a Panasonic.
How can I copy the first weld to the second, third, and fourth welds? Also, I have another job using the same weld, except that the welds will be on a 30 degree angle.
Kevin Summers from Miller Welding Automation, An ITW Company - Business Development Manager-Automation
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Your best solution will be to contact the robot OEM for information on specific program questions.
Panasonic
909 Asbury Drive
Buffalo Grove, IL 60089
Phone: 847.495.6100
Technical Assistance: 847.495.6200
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