INTRODUCTION

The most prominent advantages of automated welding are precision and

productivity. Robot welding improves weld repeatability. Once programmed
correctly, robots will give precisely the same welds every time on workpieces of
the same dimensions and specifications.

Automating the torch motions decreases the error potential which means decreased
scrap and rework. With robot welding you can also get an increased output. Not only
does a robot work faster, the fact that a fully equipped and optimized robot cell can run
for 24 hours a day, 365 days a year without breaks makes it more efficient than a
manual weld cell.

1. SAFETY REQUIREMENT IN ROBOTIC WELDING CELL

SAFETY STANDARDS FOR ROBOTIC WELDING

• Specification for Arc Welding Safety

• Guide for Components of Robotic and Automatic Arc Welding Installations
 • Risk Assessment Guide for Robotic Welding

Welding is an established manufacturing process with known potential hazards.

Potential safety hazards associated with arc welding include arc radiation, air
contamination, electrical shock, fire and explosion, compressed gases, and other
hazards. Robots were originally designed to perform the job functions of a human.
Robots can replace humans in the performance of dangerous jobs and are
considered beneficial for preventing industrial accidents. On the other hand, robots
have caused fatal accidents.

One of the best solutions for robot safety is to purchase a complete welding cell
from a robotic integrator . A complete cell includes barriers, all necessary safety
devices, and a method of loading and unloading the workstation.

Each robot installation must be carefully planned from safety view point to
eliminate hazards. When the robot is in operation it is necessary that people remain
outside the work envelope. Barriers or fences should be in place around the robot.
All doors and maintenance openings must be protected by safety switches, and the
weld areas must be safe guarded so that the power is immediately removed from
the robot when a door is opened. Emergency stop buttons should be placed on all
operator panels, robot cabinets and robot programming panels. Barriers be
designed to completely surround the robot and eliminate the possibility of people
climbing over or under to get inside the barrier. Signal lights must be arranged on
the robot or in the robot area to indicate that the robot is powered.

This project expect systems integrators to conduct a risk analysis and then design
and adjust systems for the safest operation that meets or exceeds all plant, federal,
state and local codes. These safety measures include fence barriers, gate interlocks,
floor safety switch mats, photo-cell and light curtains, fixed guards, emergency
stop hardware and software, as well as frames and screens to protect workers from
welding arc flash.

2. APPROPRIATE PROTECTIVE DEVICES

Another asset a systems integrator can offer is access to multiple equipment

options and configurations that ultimately lead to better productivity. Some
integrators offer pre-engineered or standard work cells. These systems provide out-
of-the-box affordability, but are not always the right solution when customization
is required. Integrators with flexible, modifiable work cells can provide a cost-
effective solution tailored to the application.

Robotic system

• Position

The positioner determines how the part is presented to the robot for welding.
Typical positioner types include stationary tables, turntables, headstocks, tailstocks
and Ferris wheel types.

• Fixtures

These hold the part to proper tolerances for welding. Unique to each automation
project, fixtures are only as good as the quality and innovation the systems
integrator puts into them. When selecting a robot, the integrator considers
accuracy, speed, reach, operator interface and the various options available with
each robot.

• Base Platform

A common base platform, which the systems integrator designs and constructs,
connects all components. It is also a base for controls, flash screens, barriers and
safety components.

• Operator Interface
This is the final component of the work cell. Simple push buttons, or a touch-
screen panel, are often recommended interfaces

Technician

This is important methods for ensuring worker safety is adequate training

conducted by the systems integrator. A hands-on, mentoring approach works well
with employees in the welding industry who are comfortable working with their
hands. While some formal classroom training is needed, the majority of the
teaching should be done on the equipment when it is set up at the systems
integrator's facility.

Training levels vary in what the integrator provides. There is basic operation
training for work cell and robot operation, and advanced training for robot
programming, maintenance training and welding training.

The industry standard is one week for each of the training courses. The ideal
learning environment is a class tailored to the specific needs of each trainee along
with one-on-one interaction with the instructor/mentor. Retraining, introduction to
new techniques and refresher courses are other benefits systems integrators offer
customers.

3. ROBOTIC WELDING CELL SAFETY BARRIER SYSTEM

Three types of safeguarding devices that can be used as part of a comprehensive

safety system for robotic welding setups.

• Safety light screens

 • safety interlock switches

• two-hand controls

Safety light screens

A light screen is an optoelectronic device used to protect welders from a

machine hazard. The basic elements of a safety light screen, or safety light curtain,
are an LED emitter array and corresponding phototransistor receiver. They produce
a "screen of light" with a specified resolution that detects intrusions into the
sensing field. When a object such as an arm or hand is detected, it generates a stop
signal to the machine control. This sensing field is installed between the hazard
and personnel, at a distance from the hazard such that an individual cannot access
the hazard.

Interlock switch
 Safety interlock switches monitor the position of a guard or gate, and they
are used to shut off power, control personnel access, and prevent the machine from
starting when the guard is open. While hard guarding includes fixed and adjustable
guards, safety interlock switches can be used with interlocked guards.

Interlocking guards (such as doors, gates, and covers) can be moved and often are
used when frequent access within the guard is needed. Guards that can be moved
or removed generally need to be interlocked, preventing an accident from
occurring if someone tries to access a guarded area.

A movable interlocked guard is recommended if operators need intermittent to

frequent access to a hazardous area. If the guard is moved or opened, the interlock
switches prevent cycle initiation or send a stop signal to the machine control. By
locking the guard closed or in position, some interlock switches can also prevent
access to the machine until it comes to a safe stop, maximizing safety by further
protecting operators from potential injuries.

two-hand controls
 Two-hand control systems comprised of two actuating buttons (or hand
controls) and a safety module are used to activate a machine and prevent false or
unintended cycles. When both buttons are concurrently actuated within ½ second,
via mechanically based buttons or ergonomically designed buttons, a signal is sent
to initiate and control a machine cycle.

Along with preventing unintentional machine actuation, two-hand controls can

function as a safeguarding device by physically engaging both of an operator's
hands, keeping them out of harm's way when a machine is operating. If an operator
releases one or both actuating buttons, the safety module (or other logic device)
immediately stops the machine cycle.