Arc Welding Robots vs. resistance welding process
Before we jump on the topic, “Arc Welding Robots vs. resistance welding process”, let us be clear about what are they exactly and how are they going to be helpful for your industrial work.
Arc Welding Robots
Almost 20 percent of the total welding applications were covered by arc welding robots. While different types of processes include arc welding, they include the constant connection of metals with electricity. A power supply of solder produces the energy necessary for the creation of an electric arc between the electrode and base metal.
The electric arc generates the heat required for melting the metals. They are fused together when metals have cooled down.
Applications for arc welding include MIG, TIG, cored flux, and plasma welding applications. Two common welding robots for automating arc welding applications are the FANUC Arc mate 100i and the FANUC Arc mate 120i series.
A consumable or non-consumable electrode is used, depending on the specific type of arc welding application. Some methods for arc welding require the use of filler metals, while others do not. Since arc welding requires more consumables, all robotic welding processes also cost more.
Additional drawbacks for arc welding are that they can take longer, require work piece surface finishing, and can pose a risk. Because of the flow used, slag often forms on the joints of the solder and must be removed with a clean welding operation. Intense arc light and excess heat provide hazards from arc welding.
FANUC Arcmate 120ic automation removes operators from these threats, but further safety remains essential. This is why many users also want to include the joint robot in a soldering cell and to protect floor staff. A wide range of metals can be welded irrespective of thickness or position, the benefits of arc soldering included. Processes of arc welding can be used for mixing various metals or thicker metals. It makes an extraordinarily long-lasting solder.
Many robots are typically six-axis arc welders. Moreover, several sold robots for welding are installed into a supply of robotic welding. The finalized sold FANUC welding robots with integrated Lincoln Powerwave 350, i400 or Powerwave 455 m are very popular. The most widely used sold Modern welding robots have a soldering supply manufactured by Miller such as the Auto-Axcess 450.
Resistance Welding Process
The majority of welding applications automated with robots require resistance spot welding. In comparison to a form of liquid state soldering by arc welding, robotic spot soldering requires the solid joining of metals. Metal parts are fastened together under pressure during spot welding. An electric current produces the work piece’s resistance, which contributes to heat and a continuous fusion. In contrast to arc soldering, spot welds are focused on a small work piece area.
In addition to automotive production lines, the FANUC R-2000iC is usually found for spot welding automotive components. Spot welding uses a non-consumable electrode to create a current without using filler. Robot spot welding is more economic than arc soldering with fewer consumables and less set-up. It is also a faster process than arc welding, as soldering can be achieved in seconds and no slag must be removed.
Another benefit of spot welding over arc welding is that it effectively uses less heat and focuses this heat on the unique surface of the component. Focusing heat on one position often decreases the metal’s chance of distortion.
Several FANUC robots for sale are already equipped with spot welding equipment as they have been withdrawn from long car lines. Robotic resistance soldering has certain drawbacks. The metal forms to be welded are restricted to stainless steel and steel. Spot soldering for metals thicker than 3 mm is not recommended, which is why it is used mostly in sheet metal welding.