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Automating the torch motions decreases the error potential which means decreased
scrap and rework. With robot welding you can also get an increased output. Not only
does a robot work faster, the fact that a fully equipped and optimized robot cell can run
for 24 hours a day, 365 days a year without breaks makes it more efficient than a
manual weld cell.
One of the best solutions for robot safety is to purchase a complete welding cell
from a robotic integrator . A complete cell includes barriers, all necessary safety
devices, and a method of loading and unloading the workstation.
Each robot installation must be carefully planned from safety view point to
eliminate hazards. When the robot is in operation it is necessary that people remain
outside the work envelope. Barriers or fences should be in place around the robot.
All doors and maintenance openings must be protected by safety switches, and the
weld areas must be safe guarded so that the power is immediately removed from
the robot when a door is opened. Emergency stop buttons should be placed on all
operator panels, robot cabinets and robot programming panels. Barriers be
designed to completely surround the robot and eliminate the possibility of people
climbing over or under to get inside the barrier. Signal lights must be arranged on
the robot or in the robot area to indicate that the robot is powered.
This project expect systems integrators to conduct a risk analysis and then design
and adjust systems for the safest operation that meets or exceeds all plant, federal,
state and local codes. These safety measures include fence barriers, gate interlocks,
floor safety switch mats, photo-cell and light curtains, fixed guards, emergency
stop hardware and software, as well as frames and screens to protect workers from
welding arc flash.
Robotic system
• Position
The positioner determines how the part is presented to the robot for welding.
Typical positioner types include stationary tables, turntables, headstocks, tailstocks
and Ferris wheel types.
• Fixtures
These hold the part to proper tolerances for welding. Unique to each automation
project, fixtures are only as good as the quality and innovation the systems
integrator puts into them. When selecting a robot, the integrator considers
accuracy, speed, reach, operator interface and the various options available with
each robot.
• Base Platform
A common base platform, which the systems integrator designs and constructs,
connects all components. It is also a base for controls, flash screens, barriers and
safety components.
• Operator Interface
This is the final component of the work cell. Simple push buttons, or a touch-
screen panel, are often recommended interfaces
Technician
Training levels vary in what the integrator provides. There is basic operation
training for work cell and robot operation, and advanced training for robot
programming, maintenance training and welding training.
The industry standard is one week for each of the training courses. The ideal
learning environment is a class tailored to the specific needs of each trainee along
with one-on-one interaction with the instructor/mentor. Retraining, introduction to
new techniques and refresher courses are other benefits systems integrators offer
customers.
• two-hand controls
Interlock switch
Safety interlock switches monitor the position of a guard or gate, and they
are used to shut off power, control personnel access, and prevent the machine from
starting when the guard is open. While hard guarding includes fixed and adjustable
guards, safety interlock switches can be used with interlocked guards.
Interlocking guards (such as doors, gates, and covers) can be moved and often are
used when frequent access within the guard is needed. Guards that can be moved
or removed generally need to be interlocked, preventing an accident from
occurring if someone tries to access a guarded area.
two-hand controls
Two-hand control systems comprised of two actuating buttons (or hand
controls) and a safety module are used to activate a machine and prevent false or
unintended cycles. When both buttons are concurrently actuated within ½ second,
via mechanically based buttons or ergonomically designed buttons, a signal is sent
to initiate and control a machine cycle.