Electron Beam Welding Robots



Publicado el 19/05/2014

Electron beam welding robots are effective in a variety of different welding solutions. Due to their focused weld zone, they are provide precise, highly controlled welds. View our collection of electron beam welding robotics here:http://www.robots.com/applications/el…

Electron Beam Welding Robots: Electron beam welding (EBW) is a fusion welding process that joins two materials by using a beam of high-velocity electrons. The electrons produce kinetic energy that is transformed into heat upon impact, melting the workpieces and connecting them with a fusion weld.

Electron beam welding robots are effective in several different welding situations and they have a narrow weld zone. With such a focused welding zone, it allows for highly controlledwelding.

The electron beam is generated in a high vacuum. While it can weld in medium or non-vacuum conditions, high vacuum welding will provide maximum purity and high depth to width ratio welds.

There are several robot models available that can perform electron beam welding, including the FANUC S series and the Motoman UP series.

Source: RobotWorx Marion

New Motoman robots at Schweißen & Schneiden – Slim and fast

January 2014. At the Schweißen & Schneiden trade fair Yaskawa presented new 6-axis robots for arc welding, handling, laser welding, cutting and surfacing: the Motoman MA1440, MH12 and MC2000.

With these new developments Yaskawa is effectively reacting to the continued pressure for efficiency in the automotive and related industries. The robots work with a high level of precision and an exceptionally high number of cycles. Because they have a smaller footprint, they can be positioned closer together on the production line.

Handling with the Motoman MH12

The new Motoman MH12 handling robot unveiled in Essen is the fastest model in its class. The innovation is designed for a 12 kg lifting capacity – twice that of its predecessor. With the hollow wrist Yaskawa has greatly facilitated media feed to the gripper. Interference contours from externally routed media cables are thus a thing of the past. The mechanical load of the cabling is also significantly reduced. The Motoman MH12 nevertheless offers the servo float function and is thus ideally suited to use on injection moulding machines. The slim design results in a small footprint and permits a high robot density.

Arc welding with the Motoman MA1440

Due to the Motoman MA1440 newly conceived arm design, the six-axis robot is particularly space saving in operation and extremely fast, with a high lifting capacity. In fact, the latter has doubled to 6 kg compared to previous models. This enables the basic MA1440 model to be equipped with powerful welding torches that could hitherto only be used with larger robots. The application-specific uses, in particular in the automotive and automotive supply industries, are correspondingly diverse.

The total speed of all six axes of the MA1440 is higher than before. In particular, movement in the secondary process time was greatly accelerated. This results in significantly longer cycle times.

Due to its completely newly conceived robot arm, the Motoman welding robot is predestined for use in industries with a high pressure for efficiency. It requires significantly less space than conventional kinematics for comparable tasks. The robot can thus be placed closer to the workpiece or even behind it. Furthermore, the diameter of the hollow wrist axis has been increased by almost 20 per cent, offering even more freedom for the welding packages.

Laser welding, cutting and surfacing with the Motoman MC2000

The Motoman MC2000, a robot specially designed for tasks that require a high degree of precision, made also its debut at Schweißen & Schneiden. Thanks to precise drives and special gear box it achieves a high level of stability with ultra-precise positioning and path accuracy. These properties are particularly appreciated in laser applications – whether it is laser cutting, welding or surfacing.

Laser remote welding is an application that is currently experiencing increasing demand. With its lifting capacity of 50 kg the new MC2000 enables large laser heads in different to paths hover precisely over the workpiece. ‘On the fly’ programming of Trumpf and Highyag laser heads can be carried out not only with external PC software, but directly online via the hand-held programmer of the DX100 robot controller. The laser head and robot run simultaneously, combining their speed and creating the cutting contour together. What makes it so special is that tight circles and curves, as well as broad paths can be run without a break. The result is always accurate. The robot not only positions the laser head, but runs its path synchronously to the laser head over the workpiece.

Multi-robot technology in the controller permits the synchronous operation of up to eight robots or 72 axes. Fast motion sequences with the Motoman MC2000 and high path accuracy reduce cycle times and substantially increase the quality and output of components.

Source: IFR

Global Influences on Power Source Technology. Robotic arc welding

I’ve heard from several users that are curious about the global arc welding market. Globalization of manufacturing is here to stay, but does it affect robotic arc welding which is all about Amps, volts and travel speed? There are regional differences between continents that affect the development of welding power source technology:

Japan – Low Spatter

Japan uses straight CO2 shielding gas for most of its GMAW welding. This forces short circuit transfer, and Japanese power source technology has been concentrated on reducing spatter with CO2. Argon is approximately 7x the cost of CO2 in Japan and only 3x the cost in the USA. Japan pioneered the “controlled short circuit” technology which is marketed by most companies today (RMD, STT, etc.). When the Japanese do use pulse, it is normally with an 80/20 Ar/CO2 gas mix which is not commonly used in other regions. The fast pace of changing technology means it is often practical to replace power sources when they are less than 10 years old, due to improved performance vs. cost of repair (similar to computers).

Europe – Perfect Pulse

Pulse welding was developed to provide a spray transfer arc at a lower average current. European pulse technology is focused on creating the ideal “one drop per pulse” arc. They use 90%+ mixes of Argon shielding gas and feedback from the arc to pulse current and spray a molten droplet across the arc, while reducing down to a lower background current. The weld parameters are normally set in the power source, and the robot selects schedules or jobs from the power source and then turns the arc on/off during motion. This means the power source has closed loop control of the process, while the robot is just performing motion control. In Asia and the Americas, it is common for the weld parameters to be stored in the robot program itself, and the robot controls the sequence of the weld power.

North America – Faster

Pulse welding and a spray arc do not have spatter; however, the wider spray arc can result in undercut if the travel speed is too fast. The controlled short circuit arc also reduces spatter, but it relies on interaction with the weld pool, and faster speeds create arc instability and generate spatter. US brand welders have multiple pulse modes (with cool names) that operate with shorter arc lengths. They pulse the current and then operate in short circuit mode with recommended gas mixtures around 90/10 Ar/CO2. They will generate spatter, but the pulse modes try to minimize the size and amount of droplets. It results in a balance between faster travels and trying to keep the spatter at a reasonable level.


The power sources from around the world do have some common traits, such as process libraries for algorithms to control the arc based on wire type, size, gas and pulse type. These algorithms are generally developed in a lab for specific conditions. Using an algorithm designed for 1.2 mm dia. wire with a 0.045” wire will normally work, but it may not produce the optimum arc. Regional differences in wire alloys and shielding gas may also contribute to slightly less than ideal conditions.

Does that mean you shouldn’t use power sources from other continents in your plant? Not necessarily. Power source manufacturers can tailor their equipment to regions by including algorithms for local wire and gas mixtures in their process libraries. Manufacturers setting up operations in other parts of the world should be aware of a foreign weld distributor’s ability to support welding standards designed in a different region. In the end, some flexibility in equipment and settings may go a long way toward achieving a quality weld with power source “X” in country “Y”. After all, it’s all about Amps, volts and travel speed. By Chris Anderson, Welding Product Marketing Manager – See more at: http://www.motoman.com/blog/?p=77#sthash.CVo8p8pj.dpuf


A Pennsylvania manufacturer had a problem. Their production is dependent on welding and machining processes that historically generated a significant amount of scrap and rework. The original welding and machining process was responsible for the highest amount of defects in the plant, and it had done so for the past 30 years.

The process had been in place since the plant was built in 1970. When the robotic automation project was started, the customer soon realized that no one knew what the “true” process was. Every shift had a different equipment setup, so the part production and quality differed significantly shift to shift. According to the customer, “our first step was to understand the process, evaluate new ideas and refine as needed”.

The critical welding process was completed by some rotary welders that were purchased when the plant was built. Not only did the welders have significant maintenance issues, but the welder torches had limited orientation options and generated a significant amount of rework due to pinholes in the weld.

After welding, the parts were loaded by the operator into a machine that removed the excess filler material. The material handling of a hot 75 lb. part was an ergonomic issue, and quality testing was not completed after the machining process. Any defects were detected late in the manufacturing cycle; consequently the value of the machining process was lost on any parts that were reworked.

When evaluating the process for automation, there were several sequential welding operations and final machining that required precise part alignment. It was evident that the initial part orientation could not be preserved with robot transfer. Significant process efficiencies could be gained by adding robotic handling and with a part weight exceeding 75 lbs., the ergonomic and cycle time benefits were clear.

The New Automated Process

  1. The part is made from two components that sit one inside the other. The parts are slid off a conveyor by the operator and into tooling on a rotary positioner. The operator verifies orientation of the parts one to another.
  2. After stepping clear of the light curtain, the cycle is initiated, and the turntable rotates to present the parts to an ES165D material handling robot.
  3. The handling robot picks the oriented assembly and transfers it to a Cognex based MotoSight™ 2D vision system to verify that the part is oriented correctly. After verification, the material handling robot loads the assembly into the part tacking fixture. If the alignment is incorrect, the part is placed on a reject conveyor to be adjusted by the operator.
  4. The tacking fixture clamps and centers the inner detail, allowing the first MA1400 welding robot to tack the components together. The fixture clamp retracts, allowing the robot to complete a large circular weld.
  5. The ES165D robot flips the part over and moves it to the “Side A” fixture. A spatter guard is loaded over the part, and the MA1400 welding robot makes four smaller circular welds.
  6. The ES165D robot removes the spatter guard, flips the part over and moves it to one of two “Side B” welding fixtures. It then picks and sets a spatter guard over the part. The second MA1400 welding robot makes a single smaller circular weld.
  7. The ES165D handling robot removes the spatter guard, picks the welded part and loads an open position on a cooling rack. The robot then moves to a machining center, picks a finished part and sets it on an outfeed conveyor. The robot then returns to the cooling rack, picks the coolest part, loads the machining center and starts the machining process.
  8. The process repeats.

The Solution

The custom engineered solution included the following items:

  • 2-MA1400 welding robots
  • 1-ES165D material handling robot
  • 1-Triple robot controller
  • 2-Miller Auto-Axcess® weld packages
  • 2-Binzel water-cooled torches
  • 1-ToolSight® torch alignment package
  • 1-Infeed conveyor
  • 1-Rotary indexing table
  • 1-Custom end-of-arm tool
  • 1-Fixture package
  • 1-MotoSight 2D vision package
  • 1-Controls package
  • 1-Cell guarding package

Lessons Learned

Once the customer understood their process, they began to test and try new ideas. Originally, they used a large counter bore which was expensive. Eventually, they began running carbide inserts, which lowered costs. Coolant was used with the counter bore, which caused chips to stick to the part and created a variety of process problems. After changing to inserts, parts could be run without coolant. This helped clean up and improve their process.

“Robotic machine tending has been really beneficial to us,” said the customer. With 75 pound parts, it helps with safety and ergonomics. The robot is also able to load and unload spatter guards, which protects key areas of the part during welding. The consistency and improved part quality has provided significant benefits.

The Results

The old equipment produced a part every 11-12 minutes. With the new production cell, the part can produce a good part every five minutes, far outpacing other plant production. In the words of the customer, “the parts just pile up, till they shut the cell off”.

Quality has improved significantly, and now the cell is delivering higher quality parts that don’t require the same level of cleaning before the next step in the manufacturing process.

Previously we had two people dedicated to part rework. Those personnel are no longer necessary and have been reassigned. Post machining rework due to pin holes has virtually been eliminated.

Source: Motoman

Reconditioned Motoman UP6 robot featuring NEW Miller Auto Axcess 450

Publicado el 26/03/2014

(1) Reconditioned Motoman UP6 manipulator with XRC controller
(1) NEW Miller Auto Axcess 450 welder with Tregaskiss torch kit
(1) Reconditioned Tregaskiss torch reamer
(1) 9 button operator station
Interested in a Motoman UP6 to advance your process, visit our product page here to receive a quote:http://www.robots.com/motoman/up6

Source: RobotWorx Marion

Industrial Robotic. Motoman Arc Welding

Motoman is the world leader in arc welding robotics with industry firsts such as patented multiple robot control and “Master Arc” MA-series robots.  Integrated through-the-arm cabling improves weld accuracy, improves torch access, and reduces downtime.  Motoman backs the performance of the MA-series robots with the industry’s first two-year torch cable warranty.

This patented torch cable design was key to the success of the EA series robots and is not available from other companies.  Motoman also was the first with an extended reach (>3.0 m) robot for arc welding (HP50-20) and has an extended reach MA-series robot (MA1900).

Motoman is extending the success of these arc welding arms with the introduction of the first 7-axis arc welding robot.  The flexibility of the VA1400 model can be used to reduce floorspace and achieve higher robot density for increased production.  The unique “elbow” axis of the arm also allows the robot to reach around tall parts or reach into boxy parts.

Motoman Arc Welding Robot Models