welding 1.8mm zink coated to 3.2mm tube

[hunter41]

I have a new car line started up
I am a welder and have been trainned in robot welding(mig)
I can not get the ste right to stop burn holes and a lot of rework.
Please can any one help as i have been tasked to reduce rework.

 

[Sparkey]

Hi Hunter! welcome!
Tell us some more about the robot, the welding set(s) you hook up to them, nature of the welds (spots, beads;..?) What are the parts you want to weld? etc;..
We have a robotics expert on here, Robotstar5, i'm sure he will show up soon enough!

 

[hunter41]

help

Hi Sparky
I am hooked up to fronius sets
8mm spots and 20mm Beads
4 robots making door beams
zinc coated brk to a steel tube
12 MPS
gas 14
30 welds a part
abb robots
HELP i can not stop the little holes but it is only now and again
but every part needs reworked.

 

[Sparkey]

Right...my nickname makes you giggle eh?
Ok, 12 mps.....??? is that the wire speed, meter per second? that sounds high, or you have to have a high travelspeed too? And what's the amperage then?
Or maybe a slight adjustment to your torch angle will do? more on the tube than on the plate....

Can you post any pics? if your company doesn't want that i can understand, i'm a production welder in a carpart plant too!

Blimey Robo! where's maintenance when you need them!

 

[Robotstar5]

I am hooked up to fronius sets
8mm spots and 20mm Beads
4 robots making door beams
zinc coated brk to a steel tube
12 MPS
gas 14
30 welds a part
abb robots
HELP i can not stop the little holes but it is only now and again
but every part needs reworked.

Hi Hunter, a bit more info please,
Which ABB model, S4 or S4C?
Are robots integrated e.g. wire speed, current, voltage control?

First check for any weld faults, is TCP correct?
Are parts consistant (dimensionally and clean) and presented accurately?

Just had a nice weeks holiday and now I'm thinking about work again!

 

[Sparkey]

See? told you he was THE man! Thanks Stu!
What's a TCP?

 

[Robotstar5]

What's a TCP?

Tool Centre Point - the position of the end of the welding wire relative to the face of the robot where the torch bolts on.
It allows the robot to move along the weld maintaining torch angle and makes programming (teaching) a hell of a lot easier!

 

[Sparkey]

Tool Centre Point - the position of the end of the welding wire relative to the face of the robot where the torch bolts on.
It allows the robot to move along the weld maintaining torch angle and makes programming (teaching) a hell of a lot easier!

Hmmm that rings a bell......do they call it bullseye too?

 

[Robotstar5]

....do they call it bullseye too?

No, a bullseye is a clever device that allows the robot to do a self check for TCP accuracy and correct the TCP offset in the parameters to compensate.
Maybe after a wire stick or knock on the torch has moved it slightly, it saves having to manually reset the the torch position to a known datum.
It can be set to run automatically (after so many weld cycles) or requested by the operator.
It is a relatively expensive option but will save money in the long run.

You will be pleased to hear the ABB bullseye software was written by a female!

 

[Sparkey]

Oh yeah! awesome!
We sure know how to hit the bullseye!!
(sparkey doing a happy happy joy joy dance now...)