Six-axis welding robots are vital equipment in modern automated welding production and are widely used in various manufacturing industries, especially in automotive, shipbuilding, and machining. Installing the right welding fixtures is essential for achieving precise and efficient welding operations. This article, brought to you by ATINY laser seam tracking system experts, explains how to install welding fixtures for six-axis welding robots.
1. Choosing the Welding Fixture
The selection of a welding fixture depends on the shape, size, and material of the workpiece. Welding fixtures should not only secure the workpiece firmly but also allow flexible operation of the robotic arm. Common types of welding fixtures include:
- Flat Fixtures: Suitable for simple flat welding tasks, often used for large, flat workpieces.
- 3D Fixtures: Designed to secure complex-shaped workpieces, ideal for three-dimensional or angled welding requirements.
- Custom Fixtures: Tailored for specific workpieces or welding tasks to improve precision and production efficiency.
When selecting a welding fixture, consider the positioning accuracy of the workpiece and the stability of the fixture to prevent displacement or deformation during welding.
2. Preparation Before Fixture Installation
Before installing the welding fixture, confirm the working range and workspace of the six-axis welding robot. Adjust the fixture's position and angle according to the workpiece size, fixture weight, and the robot's load capacity. Ensure the fixture's installation position provides sufficient space for the robot's operation to avoid interference or collisions.
3. Steps for Installing the Welding Fixture
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Securing the Fixture Base: Welding fixtures usually come with a base or mounting plate. Secure it firmly on the robot's worktable or base. Ensure the base is level to avoid fixture misalignment or tilting.
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Adjusting Fixture Position: Adjust the fixture's position based on the size and shape of the workpiece to enable precise securing. Use measuring tools (e.g., laser displacement sensors) to ensure the relative position between the fixture and the robot's end effector is accurate.
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Fixing the Workpiece: Place the workpiece onto the fixture and ensure it is securely held. Fixtures typically use pneumatic, mechanical, or electromagnetic methods for clamping. Ensure the contact surfaces between the workpiece and fixture are even to avoid welding errors due to uneven contact.
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Adjusting Fixture Angle and Height: If the welding task requires different angles or welding postures, adjust the fixture’s angle and height accordingly. This can be achieved through the robot's movement or manual adjustment of the fixture's installation position.
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Checking Fixture Stability: Before starting welding, conduct a thorough check to ensure the fixture is securely installed, the workpiece is firmly in place, and the fixture has not shifted due to external forces.
4. Integration with Laser Seam Tracking Systems
Modern six-axis welding robots are often equipped with ATINY laser seam tracking systems to accurately identify and track weld seams, enhancing welding precision. To ensure the efficient functioning of the laser tracking system, the fixture design should accommodate the laser sensor's field of view and working range. The fixture must avoid obstructing the scanning path of the laser sensor and ensure smooth surfaces on the workpiece and fixture to improve the accuracy of the laser seam tracker.
5. Safety Precautions
When installing welding fixtures, strictly follow relevant safety procedures to avoid injury to operators or damage to equipment. Wear appropriate protective gear and ensure the robot is powered off while installing the fixture. After installation, perform necessary functional tests to verify the robot's operational accuracy and safety.
The installation of welding fixtures for six-axis welding robots is a crucial step in ensuring the success of welding tasks. By following the above steps and incorporating advanced technologies such as the ATINY laser seam tracking system, welding efficiency and precision can be significantly improved, achieving optimal welding quality and production benefits.
