High-Precision Welding

Automated Welding Robots are equipped with a 3D vision recognition system and a robotic arm with a positioning accuracy of ±0.05 mm, ensuring accurate alignment of the welding torch with the weld seam and reducing misalignment and missed welds.

Automatic Weld Seam Positioning, No High-precision Tooling Required

Relying on 3D vision scanning technology, the robot can independently identify weld positions and groove shapes. It can automatically correct positioning deviations even when workpieces are misplaced, raw materials have dimensional tolerances, or tooling offers average positioning accuracy. This significantly cuts the manufacturing and installation costs of tooling fixtures and eliminates manual teaching and point positioning procedures.

Flexible Production with Quick Product Model Changeover

There is no need to conduct point-by-point teaching and reprogramming when replacing welding workpieces. The vision system can automatically generate welding paths after scanning and recognition, enabling production line changeover within a short period. It meets the flexible production requirements of multi-variety and small-batch manufacturing and delivers higher equipment utilization rate.

Figure 2.1 3D Simulation Diagram

Step 1: Workpiece Positioning and Equipment Initialization

The workpiece to be welded is securely fixed at the welding station. The Model 1820 3D vision welding robot completes power-on self-inspection, and the 3D vision camera enters standby mode. The control system, welding power source, wire feeding mechanism and teach programming are all ready simultaneously, waiting for the welding start command.

Step 2: Collect Weld Seam Contour Data via 3D Vision Scanning

The 3D vision scanning device mounted on the robot performs an all-round scan on the target workpiece. It captures real-time three-dimensional information of the weld seam including position, trend, width, groove shape and height deviation, accurately locates the actual weld trajectory, and avoids inaccurate positioning caused by workpiece placement deviation and dimensional errors of incoming materials.

Step 3: Real-time Transmission of Weld Data to Industrial Control Computer

Massive 3D coordinate data collected through visual scanning is transmitted in real time to the supporting industrial control computer via communication lines, which synchronously stores the original scanned images and weld point parameters.

Step 4: Intelligent Computing and Optimal Welding Trajectory Planning by the Computer

The industrial control computer is embedded with professional welding process software. It conducts noise reduction, correction, analysis and calculation on the collected 3D weld data, automatically compares preset welding process parameters, and generates an accurate and continuous robotic welding motion trajectory in combination with workpiece materials and welding technical requirements. Meanwhile, it matches corresponding process parameters such as welding current, voltage and wire feeding speed.

Step 5: Computer Issues Motion and Welding Control Signals

After trajectory planning is completed, the computer synchronously sends path instructions and welding process parameter commands to the robot control system, and links up the welding power source and wire feeder to pre-adjust welding parameters in advance.

Step 6: The Robot Automatically Operates the Welding Torch According to Instructions

After receiving the control signals, the collaborative welding robot moves precisely along the planned trajectory. The equipped welding torch travels at a constant speed following the weld path; the wire feeder stably feeds welding wire synchronously, and the welding power source outputs matched welding current and voltage. No real-time manual handheld operation is required throughout the whole process.

Step 7: Completion of High-precision Automatic Welding Operation

The welding torch performs continuous welding along the preset weld trajectory with real-time visual deviation correction throughout the process. It can automatically adjust the welding path even if there is a slight installation offset of the workpiece, finally realizing high-precision and high-efficiency automatic welding of the entire weld seam. Upon completion of one welding segment, the robot can move to the next weld position according to the program and repeat the above procedures. After all processes are finished, the equipment resets to standby mode to wait for the next operation command.

Figure 2.2 On-site Physical Object Diagram

Figure 2.3 Close-up Diagrams of Each Component

MIG welding machine

Wire feeder

Wire spool

Robot electric control cabinet

3D vision inspection

Positioner

Fixed elevation base for robot

 

 

 

MIG welding torch

 

 

Video Demonstration

 

 

 

01/

Environmental Adaptation: Operate in a dry, low-dust environment to prevent humidity or corrosive gases from affecting 3D vision accuracy.

02/

Preliminary Commissioning: Calibrate the 3D vision sensor and mechanical arm before first use to ensure smooth data transmission.

03/

Maintenance: Regularly clean the 3D vision lens and check power circuit stability to prolong equipment life.

04/

Personnel Training: Operators should learn basic parameter settings and troubleshooting to maintain efficient operation.

Company Introduction

 

 

 

 

Chuanglida is a professional manufacturer of spot welding robot complete sets and a supplier of one-stop welding workstations. Customers can purchase robots separately or opt for a fully integrated turnkey delivery solution. We are able to provide product brochures, 3D CAD drawings and robot body inspection reports. All products adopt standardized export packaging and can be shipped worldwide.

You may submit a direct quotation request, or send us your workpiece process information to obtain a customized selection solution.