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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Can the CMT (cold metal transfer) process be used on structual and / or bridge beams or is it meant for mainly thinner materials?
Stefan Mayr from Fronius - Robotics/Integration
mayr [dot] stefan [at] fronius.com
Cliff,
The CMT process is a very "cold" short arc process and developed for thinner materials. The system itself is capable of doing also Puls, CMT, CMT Puls, CV.
That said: You can use the system up to 500A. If the material gets thicker you can switch from CMT to CMT Puls or just Puls.
PS: CMT is used also for gladding applications due to the very low dilution.
Please feel free to contact us direct at Fronius USA
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We are the leading manufacturer of seamless and welded pipe fittings in India. We are considering introduction of robotic welding for welded elbows which we make from CS,SS and Alloy Steels from 8" dia to 66" diameter, and thicknesses from 6 mm to 22 mm or so. So far we have been doing manual SMAW welding, first from inside and then back-chipping and final welding from outside. All welds are 100% radiographed.
We are not sure whether robotics is feasible in our application. We would like to have your views and whether you have supplied robotic systems for such an application. Our main concern is that robotic welding means single side welding (from outside) , so how do we get a radiographically acceptable joint?
If you have any feedback or comments , we would be pleased to hear from you.
Erik Nieves from Motoman Robotics - Technology Director
erik [dot] nieves [at] motoman.com
Good day. Motoman's facility in India has extensive experience applying our specialized arc welding robots to solve process problems such as yours. Mr Ken Imamura will gladly assist you. He can be reached at ken.imamura@motoman.co.in or dial +91-124-414-8514
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Is there any difference between heat energy and heat input? What is the mechanisme of welding by +ve polarity in MMA (SMAW)?
Wes Doneth from Fronius - Tech Support Manager
doneth [dot] wesley [at] fronius.com
Energy is the volts and amps required to make a welding arc (Watts). Heat input is the Volts and Amps along with time used to perform a weld. The values all play an important role in the Heat (joules) input into the base metal. I am not clear on the question concerning + polarity MMA (SMAW) welding. Electrode positive is determined by the electrode type as some electrodes require Electrode negative and some may be used on Alternating Current (AC). AC is used sometimes on Low hydrogen electrodes where Arc Blow is occuring.
Wes
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Why is a TIG process not suitable to weld carbon steel?
On metal 1.2mm welding to 2.5 metal, what is the best schedule to start with? The system came in at 140 Amps and 25 volts. The voltage seems high and the weld seems 100% spray transfer.
Wes Doneth from Fronius - Tech Support Manager
doneth [dot] wesley [at] fronius.com
Hello,
If the metal is steel it does seem quite high on the voltage. Normally this thickness of metal is done with short arc MIG 17-20 volts or if you use Pulse MIG can be very effective. I would need some more information on wire diameter and shielding gases to make a more accurate recommendation. Is the equipment capable of Pulse or at least synergic?
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I am involved in the process of making large plastic tanks for the sewage industry but also have a good electrical background. I would like to automate the production of the tanks being produced as there is a serious lack of skilled workers in my area. The tanks range from 1m height to 6m height and roughly the same diameter.
I was wondering if you could recommend whether to base my robotic welding process through the movement of the tank or the movement of the robot. The same welding arm will have to reach 6m down to weld the base of the tank but also have the flexibility to weld the flanges onto the outer of the tank and the roof on the top.
Have you ever encountered robotic welding on such a large scale or is the feasibility of this production process too hard to determine?
from Ellison Technologies Automation
Andrew,
We generally move the robot to the work, but we have also moved the work to the robot. It comes down to economics. What is the most economical way to do it. We offer some standard robot positioner to do this type of work.
Troy Sather - Ellison Technologies Automation
Integration Manager
402-650-5242
from 80-20 Group, LLC
I would recmmend you contact Efi Lepel at Smart TCP. They attach the robot to a gantry allowing easy access to your part dimension range and they have software to allow for auto programming from your drawings, utlizing the appropriate sensor.
from Motoman Robotics
Andrew,
You mention that you make large plastic tanks, but you describe fabrication techniques for welding steel tanks. I am not sure if you fabricate tanks and then line them.
If the tanks are round, you may be able to perform the welding of seams and flanges with simple turning rolls and gantries. This is simpler than robotics and available from vendors such as Jetline.
If the tank is contoured or square it may be better suited to robotics. Generally, structures the size of what you describe will use a combination of positioners to move the part and a transporter to move the robot to the part.
Regards,
Chris Anderson, Motoman Inc.
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I need to weld pipe branches onto a main pipe. The host pipe is 7 m long with two joint connections. The pipe could have a bow of uo to 7 mm. I would like to use an ABB weld robot. Which equipment can communicate with the robot to track the seam movement due to the variable bow?
from Motoman Robotics
All robot companies have some type of seamtracking system. Most are flexibile enough to work with different weld equipment. You should contact ABB directly if you have a specific robot you are trying to add this functionality to.
Chris Anderson
Motoman Inc.
from Wolf Robotics & Rimrock Corp.
We work with ABB robots and provide numerous types of seamtracking capabilities. If you're still looking for a solution please contact us so we can evaluate your requirements. Sorry for the delay in getting in touch.
Wes Doneth from Fronius - Tech Support Manager
doneth [dot] wesley [at] fronius.com
It is possible to use seam tracking with our welding powersource that ABB has available. It does depend on your ABB system whether it can be upgraded to do this. You may also be successful to use touch sensing.
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I have a Motoman MRC with no manuals and I would like to know how to relabel the universal outputs from the teach pendant to show what they actually do.
from 80-20 Group, LLC
You can buy manuals for your robot on-line at Motoman.com. Go to the Customer Satisfaction area and sign-up for internet commerce.
from Motoman Robotics
You can also contact Motoman service hotline 937-847-3200 for answers to questions. Motoman still offers training classes on MRC robots at least once a quarter.
Chris Anderson
Technology Leader, Welding
from Motoman Robotics
You can also contact Motoman service hotline 937-847-3200 for answers to questions. Motoman still offers training classes on MRC robots at least once a quarter.
Chris Anderson
Technology Leader, Welding
from Motoman Robotics
This function allows the user to name the inputs and outputs on an MRC.
1) Press CUSTOMER.
2) Press MORE.
3) Press ORG (F5).
4) Enter the user ID number.
5) Press ENTER.
6) Press MORE.
7) Press MORE.
8) Press IN NAME (F4) or OT NAME (F5).
IN NAME - universal input name display.
OUT NAME - universal output name display.
9) Cursor to the desired number.
10) Press NAME (F4).
11) Enter the name.
12) Press ENTER.
Hope this helps,
Erik
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For Longitudinal welding on the MS pipe, which technology and power source is suitable?
from Motoman Robotics
You did not indicated the thickness of the pipe. For thinner gage material or root passes the controlled short circuit transfer of Miller RMD or Lincoln STT can be advantageous. These power sources also provide pulse modes which can be used on cover passes or thicker material.
Chris Anderson
Motoman Inc.
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I am wanting to automate the welding process we have. it involves the welding of auger flights, can you assist?
from Ellison Technologies Automation
Dennis,
We would be willing to team up with you to automated your welding process.
Sales
John Burg
Ellison Technologies Automation
Office = 712-388-6300
Cell = 630-258-0978
jburg@ellisontechnologies.com
www.ellisontechnologies.com
from Motoman Robotics
Yes, we have done robotic welding (and plasma cutting) of augers on several occasions. There are several variables we can discuss including welding power supply, material type and thickness, ID/OD of the auger and post, pitch distance vs continous flight, etc. Take a look at www.motoman.com for examples of our wedling robots and cells - especially at the AW6000 series. Or feel free to contact me at 937.287.5060. Erik
from Reis Robotics USA, Inc.
Dennis, We would be happy to help you out. Check out www.reisrobotics.com or give us a call at 847-741-9500. We have a few demo systems we can do testing with as well.
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We have a robotic cell equipped with a Miller Axcess 675 and we would like to achieve some specific requirements for the welding by overwriting the pick voltage of the power supply to around 50-52V with 2.0-2.1 milliseconds pulse width. We use .052 wire with 90Ar+10CO2. I would be interested in different opinions you may have regarding the usage of this high peak voltage and potential problems that may arise during production. Thanks, Jeff.
Kevin Summers from Miller Welding Automation, An ITW Company - Business Development Manager-Automation
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Jeff,
You are able to create custom programs on the Axcess platform using the software tool, Wave Writer. This tool allows you to change peak, background, pulse width and frequency to achieve the desired wave form. We have many standard programs in the machine for 052 wire using 90/10 gas that will give you a good base line if you are looking to do something special. Please call our application hotline for more information. 866-931-9733
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I have a old Miller robot. It will arc fault for no reason. I have checked grounds, changed liner, checked wire feed. I can't find anything. Please help me. Thank you
from Ellison Technologies Automation
Tammy,
95% of the time the issue turns out to be the welder, not the robot. Focus on the welder cabling. Have you tried a new wire drive cable? The next time it happens, see if you can feed wire.
Thank you,
Troy Sather
Integration Manager
Ellison Technologies Automation
2906 21st Avenue
Council Bluffs, IA 51501
T 712.388.6988
M 402.650.5242
F 712.388.6989
www.ellisontechnologies.com
tsather@ellisontechnologies.com
from Motoman Robotics
What kind of robot is it exactly? Look on the robot arm itself for a tag. Miller didn't really make robots, so chances are that it was built by OTC. If it is a robot problem, perhaps they can help. http://www.daihen-usa.com/products/arc/
Of course, that robot is quite old and it may be time to replace it. Check out www.motoman.com for welding robots.
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