Programming Errors
Cause: If incorrect data is input during programming or if there are errors in the programming logic, the robot may follow the wrong path during welding.
Solution: Carefully verify the programming data, ensuring all coordinate values and path parameters are correct. If necessary, use offline programming software for simulation verification before uploading it to the robot.
Mechanical Errors
Cause: After long periods of use, wear and tear or loosening of the robot’s joints can lead to a decrease in positioning accuracy, causing weld misalignment.
Solution: Regularly maintain the robot, check and tighten all connection components, and replace any severely worn parts if needed. Calibrate the robot’s position sensors to ensure accurate measurements.
Improper Workpiece Clamping
Cause: If the workpiece is not securely fixed or clamped inaccurately, it may shift during welding, affecting the weld position.
Solution: Optimize the workpiece clamping method, using reliable fixtures to ensure the stability of the workpiece throughout the welding process. The ATINY laser seam tracking system can also be used to automatically scan and detect weld seam deviation, guiding the welding torch along the correct path.
Detection and Feedback System Malfunction
Cause: Welding robots are typically equipped with vision systems or other sensors to detect the weld seam position. If these systems malfunction, they may not accurately capture the actual weld seam location.
Solution: Regularly check the sensor’s working condition, clean the lens surface, or replace the protective lens to ensure sufficient light. If any malfunction occurs, promptly repair or replace damaged components.
Improper Parameter Settings
Cause: Incorrect settings for welding current, voltage, or speed may also cause the weld to deviate from the intended path.
Solution: Set the welding parameters based on factors like the material and thickness of the workpiece. Perform test welds to find the optimal parameter combination, then apply these settings in actual production.
The problem of weld misalignment in welding robots is often the result of multiple factors working together. Therefore, in practice, it is essential to consider all possible influencing factors and take appropriate preventive and corrective measures to ensure weld quality.
