Robotics & Automation: Welding machine technology

Carl Cloos Schweisstechnik will present new welding machine and robotic technology at Euroblech 2008 trade fair. The Cold Process (CP) for thin plate welding, laser hybrid and Tandem processes will demonstrate high efficiency in robot-supported manufacture on the most varied components A feature of the GLC 353 Quinto CP high end pulsed arc welding machine is the low heat input in the weld seam

This reduces component distortion and the burn off of the coating is significantly reduced when MIG-brazing coated plates.Another benefit of Cloos CP technology is the low dilution of the filler material with the base metal when hardfacing.

The CP process offers optimised gap bridging ability and increased weld speeds, particularly when welding thin aluminium plate.The MIG/MAG Tandem process developed by Cloos offers advantages for universal welding tasks.

Two micro-processor controlled GLC 603 Quinto pulsed arc power sources are electronically synchronised, feeding two electrically insulated weld current circuits, making it possible to set the welding parameters separately for each arc for an optimum process run.

This results in good seam quality with low spatter, increased deposition rates and high weld speeds.The laser hybrid welding head with an integrated seventh robot axis provides optimum torch orientation, ensuring easy tracking of the weld seam, even when changing welding direction and a good coupling of the laser beam in the required MIG/MAG torch position.

This avoids unwanted welding interruptions on contours and ensures shorter cycle times for the robotic welding process.The integrated process monitoring sensors offer excellent potential for a greater variety of seam types in universal application.

The 20kW laser gives an advantage when welding thick components made from different materials.Combined with the synergy-controlled pulsed arc power sources in the Qineo-Pulse series, Cloos will demonstrate the high-capacity process Rapid Weld.

As a result of the constricted high capacity spray arc, deep penetration with high deposition rates can be achieved at high wire feed speeds.The process is suitable for high capacity welding of thick walled steels.A flexible overhead mounted Romat 320 industrial robot will demonstrate high capacity plasma-arc cutting using offline programming.The 280A plasma-arc power source Hifocus 280 is equipped with a swirl-gas fine focus torch and cuts bevels with angles between 0-45deg quickly and with a low oxygen consumption.

Therefore both mild steel and high-alloy steel with material thicknesses of 0.5 to 50mm can be cut cleanly and burr-free.For the weld seam preparation on unalloyed steel, the oxygen cutting technology ensures metallurgically perfect cutting surfaces that do not require cost-intensive rework.Plasma-arc cutting with Hifocus technology has a quality similar to the laser process and a very high cutting speed.Using the Moses offline programming system, robot cutting and welding tasks can be programmed in seconds.

The system can automatically calculate complex tube penetrations and cuts and generate complete robot programs, including synchronous control of component positioners and measurement of component tolerances by the robot.Moses can generate cut outs on tubes, containers and base plates with weld seam preparation as efficiently as the welding paths when welding tube sockets. Cutting using Cloos robots will become more economical even for the smallest production batches. High-capacity Cloos laser sensors will be demonstrated in a nine-axis robot welding system.

The Romat 350 industrial robot has a 1.5m linear track that extends the working range for optimum operation. The CSE sensors are non-contact, optical measuring systems for seam tracking and determination of weld position/geometry when robot welding.

They operate on the basis of a distance measurement using a low-capacity laser beam (up to 50mW). The search process of the CSE sensor is effected offline before the actual welding starts.

The workpiece is scanned, the return signal is electronically evaluated and significant positions are recognised. During welding the weld parameters are adapted in line with the previously determined seam geometry.

Cloos will also present two versions of its modular welding power sources with synergy mode from the Qineo series. The manual Qineo Step welding machine from 180 - 600A is suitable for use in industry and commerce.

In synergic operation mode the welder can use the factory-programmed parameter settings (synergic characteristic curves) where, depending on the step-switch position, all the adjustments relevant to the welding process are stored.

The step-switch series is available in compact design or in the capacity range from 350A and above with a separate wire drive unit for a larger work radius.