Applied Welding Engineering:

Robotic Arc Welding

Lecturer:
Dr Ing Yupiter HP Manurung

Group Members:

Emi Rozaili B. Ramli 2005388606

Amir Hazwan B. Hamzah 2005389005
Mohd Taufik B. Asli 2005388302
Mohd Farziq B. Mohd Al’dilah 2006882607
Zairee Ezzam B. Zahuri 2005388439
 Introduction
Robotics Terminology
2. Robot:
An electromechanical device with multiple
degrees-of freedom (DOF) that is programmable
to accomplish a variety of tasks.
l Industrial robot:The Robotics Industries
Association (RIA) defines robot in the following
way:
“An industrial robot is a programmable,
multi-functional manipulator designed to
move materials, parts, tools, or special
devices through variable programmed
motions for the performance of a variety of
1. Robotics:
The science and technology of robots, and their
design, manufacture, and application.
ASIMO, a humanoid robot manufactured
by Honda
 Robotic Welding

The use of mechanized

programmable tools (robots), which
completely automate a welding
process by both performing the weld
and handling the part.
ABB Robot Arc Welding
Automation of Welding
Automation of welding became possible
and practical with the acceptance of
continuous electrode wire arc welding
processes.
The advantage of automation welding
is:
 Consistency of quality welds
 Repeatability
 Reduction of production costs
 Fewer scrapped parts
The robotic welding automation commonly
have five stations that is:
 Arc Welding

 GMAW (Gas Metal Arc Welding)

 GTAW (Gas Tungsten Arc Welding)

 Laser Welding

 Spot Welding
 Automation of Welding
Automated welding system consists of:
2. Welding arc

3. Master controller

4. Arc motion device

5. Work motion device

6. Work holding fixture

7. Welding program

8. Consumables
Some of the equipment of the robotic
Robotic Welding Concept
A special kind of electrical power is
required to make an arc weld.
 The nozzle of the torch is close to the
arc and will gradually pick up spatter.
 A torch cleaner (normally automatic) is
often used to remove the spatter.
 All of the continuous electrode wire arc
processes require an electrode feeder
to feed the consumable electrode wire
into the arc.
 Robotic Welding Concept
 Welding fixtures and workpiece manipulators
hold and position parts to ensure precise
welding by the robot.
 The productivity of the robot welding cell is
speeded up by having an automatically
rotating or switching fixture
Workcell
Typical Arc Welding Robot
 ARC MOTION DEVICES
The machine moves the arc, torch and
welding head along the joint.
The person or operator performs a
supervisory role and may make adjustments
to guide the arc, manipulate the torch and
change parameters to overcome deviations.
Since the person is partially removed from the
arc area, higher currents and higher travel
speeds can be used.
The fatigue factor is reduced and the operator
factor is increased. Productivity increases with
a resulting reduction of welding costs. Arc
motion devices fit into 5 categories:
 - Manipulator (boom and mast
assembly)
 - Side beam carriages.
 - Gantry or straddle carriages.
 The arc motion devices carry the welding head
and torch and provide travel or motion relative to
the weld.
 They are used for continuous wire processes, gas
metal arc, flux-cored arc and submerged arc
welding and also for gas tungsten and plasma arc
welding.
 The motion device must be matched to the
welding process.
 Gas tungsten and plasma arc welding require
more accurate travel and speed regulation.
 This must be specified because tighter tolerances
are used in manufacturing and the equipment will
be more expensive.
 MANIPULATOR
 consists vertical mast and a horizontal boom that carries the
welding head. They are sometimes referred to as boom and mast
or column and boom positioners. Manipulators are specified by
two dimensions:
 The maximum height under the arc from the floor.
 Maximum reach of the arc from the mast.
 They are many variations of manipulators. The assembly may be
mounted on a carriage that travels on rails secured to the shop
floor. The welding power source is usually mounted on the
carriage.
 The length of travel can be unlimited thus the same welding
manipulator can be used for different weldment by moving from
one workstation to another.
 In selecting and specifying a welding manipulator, it is important
to determine the weight to be carried on the end of the boom and
how much deflection can be allowed.
 The welding torch should move smoothly at travel speed rates
compatible with the welding process.
 The manipulator carriage must also move smoothly at the same
speed. Manipulators are one of the most versatile pieces of
welding equipment available.
 They can be used for straight-line, longitudinal and transverse
 SIDE BEAM CARRIAGE
 Less expensive and less versatile than the boom
and mast manipulator.
 The side beam carriage performs straight-line
welds with longitudinal travel of the welding head.
 Side beam carriages are available with high-
precision motion depending on the accuracy used
in the manufacture of the beam and the speed
regulation of the travel drive system.
 The carriage will carry the welding head, wire
supply and so on and the controls for the operator.
 The welding head on the carriage can be adjusted
for different heights and for in-and-out variations.
 The welding arc is supervised by the welding
operator who makes adjustments to follow joints
that are not in perfect alignment.
 The travel speed of the side beam carriage is
adjustable to accommodate different welding
procedures and process.
Precision side beam carriage Side beam carriage
 GANTRY OR STRADDLE
CARRIAGES
 Gantry arc welding machines are motion devices that
provide one or two axes of motion.
 It consist horizontal beam supported at each end by a
powered carriage. The gantry structure straddles the
work to be welded and the carriages run on two
parallel rails secured to the floor.
 This provides the longitudinal motion and can be quite
long. The length of the gantry bridge determines the
width of the parts that can be welded.
 The torches are mounted on carriage that moves
along the gantry beam. This provides the transverse
motion.
 The travel speed of the carriages must be smooth and
match the welding speed of the welding process.
 The one or more welding heads on the gantry bridge
will have power travel or will have adjusting devices to
locate the head over the weld seam.
 Usually a maximum of two torches are provided for
transverse motion. And vertical motion should be
available for adjustment.
Gantry Welding Machine FSW gantry at Eclipse
Aviation for welding stringers
and spars to aluminium cabin
panels
TRACTORS FOR FLAT-
POSITION WELDING
 A welding tractor is an inexpensive way of
providing arc motion.
 Tractors are commonly used for mechanized
flame cutting. Some tractors ride on the material
being welded while others ride on special tracks.
 The tractor should have sufficient stability to carry
the welding head, the electrode wire supply, flux
and the welding controls.
 This method popular in shipyards and in plate
fabricating shops.
 The travel speed of the tractor must be closely
regulated and smooth and related to the welding
process.
 It must have sufficient power to drag cables. A
more specialized tractor carries two heads.
Figure: Welding tractor for SAW Figure: Welding tractor, gun and track.
CARRIAGES FOR ALL-POSITION
WELDING
 There are many requirements for mechanized vertical
or horizontal position welding.
 The gun is connected to the wire feeder by means of
the standard cable assembly. In this case, an oscillator
is employed to provide lateral arc motion.
 This type of welding carriage can be used in the flat,
vertical, horizontal or overhead positions.
 Adjustments can be made to align the torch to the joint
and for maintaining this alignment. The track can be
attached to the work with magnets or vacuum cups.
 A special carriage known as a skate welder is
designed to follow irregular joints contours inside
complex structures.
 Skate welder travel units are extremely compact and
carry a miniaturized wire feeder or only a torch.
 Skate welders are used for welding inside aircraft
assemblies.
Figure: Overhead Figure: Horizontal

Figure: Vertical
 Arc Welding Robot

 Arc welding robot is one of the most

common functions in industry today.
 During this process, electricity jumps from an
electrode guided through the seam, to the
metal product. This electric arc generates
intense heat, enough to melt the metal at the
joint.
 Other times the rod or wire is
composed to become part of the weld.
During the short time that industrial
welding robots have been in use, the
jointed arm or revolute type has
become by far the most popular.
 The reason for the popularity of the
jointed arm type is that it allows the
welding torch to be manipulated in
almost the same fashion as a human
being would manipulate it. The torch
angle and travel angle can be changed
to make good quality welds in all
positions. Jointed arm robots also allow
the arc to weld in areas that are difficult
 Robot Manipulator
 The robot manipulator can be divided into two
sections, each with a different function:
 Arm and Body - The arm and body of a
robot are used to move and position parts or
tools within a work envelope.
 Wrist - The wrist is used to orient the parts or
tools at the work location.
 The robot manipulator is created from a
sequence of link and joint combinations. The
links are the rigid members connecting the
joints, or axes.
 Four Type of Industrial
Robot

 Gantry - These robots have linear joints and are 
mounted overhead. They are also called Cartesian 
and rectilinear robots.  
 Cylindrical - Named for the shape of its work 
envelope, cylindrical anatomy robots are fashioned 
from linear joints that connect to a rotary base 
joint.
 Polar - The base joint of a polar robot allows for 
twisting and the joints are a combination of rotary 
and linear types. 
 Jointed-Arm -The arm connects with a twisting 
joint, and the links within it are connected with 
rotary joints. It is also called an articulated robot.
Figure of Industrial Robot
 Robot Safety
 Depending on the size of the robot’s work
envelop, speed, and proximity to humans.
 safety considerations in a robot environment
are important and particularly for
programmers and maintenance personal who
are in direct physical interaction with robots.
Control For Automatic Arc Welding
• A control system is required to run the
welding program.
• Mechanized and automatic welding have
more complicated programs and control
additional functions, including travel or
motion, torch position and fixture motion.
• Adaptive welding, which varies weld
parameters in accordance with actual
conditions, has a complicated computer
control system that include sensing devices
and adaptive feedback.
• In semiautomatic, welding a control
mechanism in the wire feeder actuates
electrode wire feed and starts the welding
current and shielding gas flow when the
welder presses the gun trigger.
 Automatic Welding Controllers
 Programmers are designed to execute a welding program. As the welding
program becomes more complex, the controller must include more
electrical circuits.
 To fully understand a welding program, it is necessary to understand the
terms used:
 Preflow time: The time between start of shielding gas flow and arc
starting(prepurge).
 Start time: The time interval prior to weld time during which arc voltage
and current reach a preset value greater or less than welding values.
 Start current: The current value during the start time interval.
 Start voltage: The arc voltage during the start time interval.
 Hot start current: a brief current pulse at arc initiation to stabilize the arc
quickly.
 Initial current: The current after starting buty prior to upslope.
 Weld time: The time interval from the end of start time or endof upslope
to beginning of crater fill time or beginning of downslope.
 Travel start delay time: The time interval from arc initiation to the start
of work or torch travel.
 Crater fill time: The time interval following weld time but prior to
burnback time, during which arc voltage or current reach a preset value
greater or less than a welding values. Weld travel may or may not stop
at this point.
 Crater fill current: The arc current value during crater fill time.
 Burnback time: The time interval at the end of crater fill time to arc
outage, during which electrode feed is stopped. Arc voltage and arc
length increase and current decreases to zero to prevent the electrode
from freezing in the weld deposit.
 Downslope time: The time during which the current is changed
continuosly from final taper current or welding current to final current.
 Upslope time: The time during which the current change continuosly
from initial current value to the welding value.
 Postflow time : Time interval from current shutoff to shielding gas.
 Weld cycle time: The total time required to complete the series of
events involved in making a weld from beginning of preflow to end of
postflow.
WELDING CONTROLLER
Robot Controller
 For robotic arc welding system, a much more
complex controller is required.
 Controller include a high speed
microprocessor since coordinated,
simultaneous, continuos motion of up to eight
axis and all welding parameters may be
required.
Robot Controller
Robot Controller
 The machine tool industry introduced numerical control(NC) years ago,
these are known a Point To Point(PTP) control system.
 Point are location in two dimension in one plane
 For arc welding robot, the arc is moved from one point to the next in
space.
 The location of the arc is known as the tool center point(TCP)
 The path of the TCP is programmed and stored in memory.
 For spot welding, pick and place and machine loading, point to point
playback is used.
 For arc welding, playback of the arc motion is a continuos path in space.
 The robot controller must be cooerdinated so that each axis movement
begins and end at the same time.
Programmer Function
 accept the input of many point locations.
 relate welding parameter to the path tought.
 store this information in memory.
 play it back to execute a welding program.
 The major points of interest are the teach
mode, memory and playback or execution.
The method of teaching or programming the robot
controller:
 Manual method: The manual method is not used for arc welding robot
but it is used mainly for pick and placed a robots.
 Walk through: The walk through method requires the operator to move
the torch manually through the desired sequence of movement. . Each
move is recorded into memory for playback during welding. The welding
parameter are controlled at appropriate positions during the weld cycle.
 Lead through: The lead through method is a popular way in
programming a robot. The robot welding operator accomplishes this
using the teach pendant. By means the keyboard on the teach pendant,
the torch is driven through the required sequence of motion. In addition,
operator inputs electrode wire speed, arc voltage, arc on, counters,
output signals, job jump function and much more. All of this function are
related to a particular point along the taught path. In this way, if the
speed of robot is changed, it is not necessary to change the time for
certain actions to happen.
 Off-line programming:
Off-line programming involves the preparation of the program on a
computer. An appropriate languages must be used. The program is
entered into the robot memory very quickly. This increase the use of the
robot,since lead-through teaching ties up the robot during programming.
Off line programming is becoming more widely used, but requires
experienced personnel.
Teach Pendant
Weld Execution
1) Weld can be made only when the power is on all components,
electrode wire is installed, and the controller is in playback or operate
mode
2) The material must be in the fixture and ready
3) Pushing the start button will initiate the operation
4) The robot will move the torch to the start point.
5) The welding equipment will begin its cycle of operation (gas preflow,
start the arc).
6) The robot controller will determine that the arc has started and then
start motion.
7) Points along the taught path will initiate other activities programmed
8) At the end of the taught path, the welding equipment will terminate the
weld program and the robot controller will determine that the
electrode wire has separated from has separated from the work
1) After this the robot will return to its home
position, ready for another cycle.
2) At this points the weld should be checked for
quality.
3) The program should be checked and edited
to improved the weld if necessary and to
minimize the air cut path and increase air cut
speed.
4) When the weld quality is acceptable and
cycle time is at a minimum, it is time to freeze
the program and start production.
 Programming Robotic
Welding

1. The PC or laptop mediates between the multi-modal input

devices (glove and speech) and the ABB robot.
2. On the input side, it runs software that translates raw voice
and glove inputs into robot controller commands.
3. On the output side, it sends RAPID commands to the robot
that contain correct position and orientation information
based on the appropriate coordinate transformations.
Performing positioning tests
 Motion and control
commands
 “Stop” or “Halt” – emergency stop
 “Disable” or “Enable” – disable or enable multimodal control

Position slaving Orientation slaving

 “Jog” with – move the robot along one of the world frame xyz axes

 “Joint [1-6]” – select a joint

 “Joint plus” and “Joint minus” - move the selected joint
 “Scale Bigger”, “Scale Biggest”, “Scale Smaller”, “Scale Smallest”, or
“Scale Normal” – change scaling
 “Move” – move to the most recently taught point
 “Home” – move to home position
 “Safe” – move to safe position
 “Unwrap” – unwrap from extreme joint position
 Programming commands
 “Teach” or “Teach weld” – append current robot position to
program
 “Teach” or “Teach weld” with – append pointed-to
position to program

 “Run” – executes entire program

 “First” or “Last” – move to first or last program position
 “Forward” or “Backward”– move to next or previous program
position
 “Modify” – modify the current program position
 “Delete” or “Delete all” – delete current program position or all
positions
 “Insert” – insert the current robot position before the current
program position
 “Wet” or “Dry” – turning welding on or off
 “Current position” – get the current program position

 Robotic sensor
 Robotic sensor is a system that detects variations in parts
and compensates for the variation by shifting the robotic
programs.
 A sensor is effective when it is difficult to keep programmed
points in consistent locations and there are part accuracy
problems requiring the operator to frequently adjust taught
robot points. When this occurs, sensors can be used to
automatically shift the welding points.

Block Diagram of fuzzy controller

End-of-arm sensor and tool centre point calibration is a
critical aspect of successful system implementation. End-of-
arm sensing, in the context of robotic welding, is used to
detect the actual position of the seam on the workpiece
with respect to the robot tool frame. 
Result of welding pool control. (a) with control ; (b) with
control
TCP-Calibration Unit(Tool
Center point)

Tool Center point calibration unit

 used to detect the actual position of the seam on

the workpiece with respect to the robot tool
frame. 
 While end-of-arm sensor based control would
appear to solve both robot accuracy and
workpiece position error problems, this is only so
if the sensor frame, end frame, and tool frame
are accurately known with respect to each other.