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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How do I set the TCP in Motoman EA1900n?
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
You can teach a TCP by programming 5 points about a fixed point. The robot will automatically calculate tool dimensions based on these intersecting points. You can follow up with the local Yaskawa Motoman office in India for manuals and training classes:
Yaskawan Robotics India Ltd.
Plot No. 426, Udyog Vihar, Phase - IV
Gurgaon, Haryana - 122 016
India
www.motoman.co.in
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I'm wondering what the best wire choice is for us? We run mild steel 1/4" - 1/2" mostly with some smaller steel (down to 20ga). I was told by my salesman that Lincoln L59 wire was good. I'm just wondering if anyone has a recommendation for a solid steel wire (no flux) for our robotic welder. The robot is the AII V6L by OTC Daihen. I believe the welder is the DP500 also from Daihen. Any favorite .045 wire choices out there for all purpouse mild steel welding? Copper coated or not?
Kevin Summers from Miller Welding Automation, An ITW Company - Operations Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Ben,
You will find a variety of solid wire manufacturers from your local distributor's brand all the way to imported wire from China and beyond. The truth is, all solid wire comes from 2 or 3 suppliers of green rod. All wire has to meet AWS minimum standards. What makes the difference in performance is the way the wire is manufactured, packaged, priced, shipped and delivered. I would recommend Hobart Quantum Arc 6 solid wire. We use it on all the Miller Welding Automation systems. Paste this into your browser.
http://www.hobartbrothers.com/product-details.html?name=Quantum+Arc%26trade%3B+6
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Spatter issues: We have a Motoman K-10 Robot with a Miller Auto-Invision2 power supply. We are welding 1 1/4" tubular steel with a .076 wall that is nocthed out at the ends to fit up to a 1" tube. We are currently welding these in four different welds as they are welded in a horizontal position, So there is a pass on both sides of the notch on the top and on the bottom.
We are using .045 Tri-mark Vantage wire. With Robot settings of 75 cm/min 167 amp and 22 v. That gives us an actual on the welder of 23v and 230 amp. Can you suggest any different settings or maybe a change in wire that could help us with these spatter issues?
Kevin Summers from Miller Welding Automation, An ITW Company - Customer Service Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Mark,
The Auto Invision 2 is a welding machine capable of pulse welding or welding in the CV Spray mode. However your material thickness and joint type probably wont lend itself to either process very well. Typically to get rid of spatter, I would recommend comming up on the voltage to eliminate the short circuits that generate spatter. You are currently only feeding 167 ipm of wire (Motoman teach pendant amps = wfs) which is very low. You might want to consider updating the welder to an Auto Axcess with RMD. RMD is a short circuit process that nearly elimniates spatter on thin guage material. The Auto Axcess is fully compatible and easily upgraded onto the Motoman robot. Please contact our application team at 920-954-3809 with any other questions.
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Do you have any idea where we can locate an FA Axis Motor including encoder for a Panasonic Robotic welder model no AW006AE2? The serial number of the motor is TF442N49 550 watts. We are told Panasonic are no longer in the UK and are having problems finding one. Our machine was reconditioned three years ago and i find it unbelievable that we cannot find one. Can you help?
Kevin Summers from Miller Welding Automation, An ITW Company - Product Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Please contact our service team. They can provide you with the help you need.
MWAservice@millerwelds.com
1-888-843-7693
1-630-653-6819
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If I want to weld carpenter custom 455 material which electrode or filler wire should I use?
Kevin Summers from Miller Welding Automation, An ITW Company - Product Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Mr. Rajput,
Carpenter SS has very special charcteristics which must be considered when selecting the filler metal for welding. Carpenter has an online resource to help select the correct filler metal. Please refrence this web address.
http://cartech.com/techarticles.aspx?id=1830
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We are using Motoman welding robot with parameter of V 22, A 130 but sometimes the welding bead found is not uniform. Please tell me the probable causes for this defect.
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
Your welding voltage is very high (22 volts) in proportion to your current (130 amps). It should be closer to 18-19 volts and the arc should make crackling sound from short circuits and generate small levels of spatter.
The current is also very low for robotic welding. You must be making a small welding bead and it can be non-uniform if the parts vary. The power source or wire make should give you some weld settings. You can contact Yaskawa Robotics India, Ltd. for assistance on Motoman robot.
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The company I work for is running a new Fronius cmt welder and we kep geting arc failers or small welds that wont hold. What could be wrong?
Wes Doneth from Fronius - Manager of Tech Support
doneth [dot] wesley [at] fronius.com (810) 220-4414
Please call our Tech Support Team at 810-220-4414 and ask for Wes Doneth. I would be happy to help you with this issue.
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I have an auto axcess 300. Can I use this machine with a fronius interface (like Rob 5000) with Kuka Robot?
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
The "auto" Axcess has a built in robotic interface with analog control similar to the Fronius ROB5000. There is a 72 pin Harding connector on the back of the welder which has connections for interfacing. The pin-out for this connector is shown in your AutoAxcess 300 manual.
Kevin Summers from Miller Welding Automation, An ITW Company - Product Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Fank,
That is a really interesting question. The Auto Axcess 300 has a 72 pin harding connector (analog) communication. You simpy have to match these signals to the robot's analog chanels and it works. Miller has connected to Kuka for years. If there is not a 72 pin Harting connector, then you have a 5 pin device net connection and you need to communicate to the robot using Device net.
Please call our factory directly for specific hook up information.
920-954-3809
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I work for a company that uses Motoman robotic welders. The robot that I operate is the newest in in the plant but it constantly keeps burning the wire up into the welding tip on the first weld of a job causing the robot to alarm out for missing arc. What could be some causes for this to keep happening?
Kevin Summers from Miller Welding Automation, An ITW Company - Product Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3809
Michael,
The first arc on a part is difficult when the ground path is not established. If the parts are loose or sitting on dirty build up, they might not make good contact on the first weld. Check grounding connnections and grounding points.
If the wire is touching at the start of the weld, it will create an unfavorable starting condition. If the last weld on the previous part left the wire stick out longer than the first weld of the next part, this is a poor condition. Check your program points & make sure the CTWD is the same on the last point & the first point. You can use a retract function after the last weld to suck the wire in & give you a touch free start. Make sure your crater condition is not leaving a ball on the end of the wire making it more difficult to light off.
Finally, check your run-in condition. How fast does the wire feed in. Does it slam in or ease into the first arc start. Check your start functions on both the robot and welder. 920-954-3809
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I am looking for information on robotics to weld up machine frames.
Samuel Bouchard from Robotiq Gripper Company
samuel [at] robotiq [dot] com (418) 563-3322
Robert, do you have pictures of what you're trying to weld? If you'd like to send me, that would be a good start to better understand. In the mean time, you can have a look at http://bit.ly/WeldingJig
Best regards,
Sam
Chuck Boyer from Wolf Robotics & Rimrock Corp. - Marketing Coordinator
chuck [dot] boyer [at] wolfrobotics.com
Please contact us with information and we will see if we can help. Or contact our regional manager Pat Clayton 678-648-2558.
Kevin Summers from Miller Welding Automation, An ITW Company - Product Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3876
Robert,
We also have a regional manager who can contact you regarding your specific reach requirements.
David Schaefer 980-253-5643
david.schaefer@millerwelds.com
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I have been given the task of making our robotic cell more effective. The 1st pass by the robot is only being applied to one side of the joint (the side with all the variations described below) then is being covered in a single cover pass. I don't find the weld quality acceptable.
This joint is a bar and plate aluminum heat exchanger with a .375 bar then a .024” braze sheet then a .125” face bar then another .024 braze sheet then repeat the stack up. This is then butted to an extruded channel that has the 60º bevel and welded. Currently my programmer tells me that because of the variance he can not lay down a good root pass like the manual operators can. Is it reasonable to expect a root pass from the robots equal to that of a manual operator? I do have good photos of the joint as tacked, as well as the current robots 1st pass, if there is a way to exchange them it likely would be a big help.
Kevin Summers from Miller Welding Automation, An ITW Company - Product & Training Manager
kevin [dot] summers [at] millerwelds.com (920) 954-3876
David,
There are many reasons the weld from the robot is not "as good as the manual welders". Mostly it is because the robot does not adjust speed or position when the joint changes. The robot makes the exact same weld, in the exact same place each time. If the joint moves, it is possible to make a perfect weld that isn't even in the joint. As you are welding multiple layers, the position is critical. If you can send some pictures that will be a big help.
Kevin.summers@millerwelds.com
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How offten should a TCP be performed?
Robin Schmidt from ABB Inc. - Chief Engineer
robin [dot] r.schmidt [at] us.abb.com (248) 391-9000
A TCP adjustment or re-definition should only need to be done if there is an event (crash or a bump or tool change of some type) that causes the tool point to change. Some system are available to do a Sanity Check quickly between part cycles to make sure the TCP is still within tolerances. If it found to be outside the user defined limits an automatic measurment and adjustment can be preformed to bring the TCP back to a true value so the process can be on target again.
Douglas Delby from Volvo Trucks North America - Automation Operator
douglas [dot] delby [at] volvo.com (276) 637-6199
Depending on your machine and torch. I recomend running a TCP when ever I change welding tips or wire. We use ABB automation and they have a TCP checking device using a beam to update the tip of the wire. I have found that just a new contact tip will make my puddle change. Also a new box of wire may have a slight change as well.
It is up to the user if they want to update the values or not. Just remember that the stick-out of your wire will be very important depending on the process you are using.
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