How to Prevent Welding Defects Caused by Excessive Current in Robotic Arms?

The principle of welding robotic arms is to introduce high-voltage current into the welding area, generating heat to fuse metal materials. If excessive current is applied or the positioning is incorrect, welding defects may occur. How can we prevent these issues?

Operating Principle of Welding Robotic Arms

The welding robotic arm operates by introducing high-voltage current into the welding area, generating heat to fuse metal materials together. This process requires an electrically conductive welding rod to transmit current, with heat generation controlled by adjusting the current intensity and duration. The arm is designed to provide stable positioning and movement, ensuring welding accuracy and consistency.

Automated welding robotic arms function based on user-programmed steps, including positioning, time parameters, motion parameters, and welding settings. These arms execute automated operations accordingly. To accommodate various manufacturing processes while saving space, welding robotic arms feature multi-axis joints for optimal movement flexibility in complex environments. Traditional welding techniques have now evolved into automated robotic welding, offering greater stability and efficiency.

In the Industry 4.0 era of smart manufacturing, automated welding robotic arms have largely replaced human workers in hazardous welding tasks. As technology advances, robotic welding has been widely adopted in industries such as automotive and engineering machinery. But how can welding quality be managed using scientific data?

Common Issues in Welding Robotic Arm Processes
The welding robotic arm process often encounters the following challenges:
Welding Defects: If the welding current is too high or too low, or if the welding position is incorrect, defects may occur.
Damaged Welding Arm: Welding robotic arms endure high temperatures and pressure, making them prone to damage over time.
Power Failures: Power failures can disrupt welding operations, requiring adjustments and recalibrations.
Control System Malfunctions: If the control system malfunctions, welding accuracy and continuity may be compromised.
Worn Welding Rods: Prolonged use can cause welding rods to wear out, necessitating replacements.

These issues can be proactively prevented through a monitoring system, coupled with proper maintenance and regular inspections to ensure the normal operation of welding robotic arms.

Solution and Monitoring Explanation

VMS-ML Machine Learning Intelligent Monitoring System
By utilizing the VMS-ML machine learning intelligent monitoring system and installing current characteristic sensors, the system performs real-time monitoring of spot welding operations. Through software-based time-domain signals, frequency-domain signals, Fast Fourier Transform (FFT), real-time surge analysis, and instant comparison techniques, the system detects normal and abnormal welding behaviors. This enables real-time monitoring and predictive maintenance, ensuring high product yield and maintaining automation efficiency.