Hi there , I'm new to robotic welding and our company has bought a motoman nx100 controlling 2 robot arms and 4 stations controlling rotation , lift etc . We manufacture stainless steel boilers mad out of 1 mm duplex stainless sheets with various connections .
The welding sets are miller axcess 300 mig sets with miller wire feed systems .
My problems are regarding welding the but seams between the dome tops to the body and what is happening is that when welding the arc is erratic and and seems to pull back intermittently which makes the weld narrow .
When it is welding nice there is no splatter and smooth and consistent , I regularly change the tips and have recently changed liners ( all binzel btw )
This problem has racked my brain for weeks and need help could it be due to angles , drive roll settings or weld settings
Any help would be appreciated , sorry for sounding armature , my background is 15 years in fabrication , mig tig etc and have a similar system whic welds perfectly .
Motoman , miller axcess 300 weld problems
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Bonny772 -
November 14, 2013 at 11:03 PM -
Thread is marked as Resolved.
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The pendant is a dx 100 , and need to say that the wire feed behind the rollers is a esab marathon PAC with the clipping conduit liner
Many thanks -
Have you called your Miller rep to see if they can send in one of their technical people to look at your settings? Motoman has weld experts that can help too.
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your process is not adjust well.
call the guy wo sold you and ask for a trainning.
Miler is good but need to be well adjust.
tk -
Just a few basic things to ask / check.
Is it going thin at the same spot every time? if not is it going thin when it's on the same weld parameter? Are both robots doing it? If not are they both welding the same parameters? maybe try adjusting the one that is going thin to be the same as the other.
personally I'd lean toward feeding issues first. feed wire into your hand let it kind of deflect the wire. you shouldnt be able to stop the wire. check to see how freely the wire goes through the conduit. If the weld goes bad in the same area bring the robot to that point and see if you can see any stress points. in world raise the robot up in the z direction and again test the wire with your hand.
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Hi!
Just few days before I had similar problem with welding stainless steel sheets (2m x 1.5m workpiece made of 1mm thick sheet, weld using 0.8mm wire).
Sometimes the welding was perfect, but on other workpiece the weld was narrow and irregular.
Two reasons were found:
1. Too high friction in the wire feeding system - particularly the spool was turning too hard.
2. The process is very sensitive to proper ground connection to the workpiece. The ground clamp attached in one place resulted with good welding performed near the place of grounding, and worse when welding 1.5m away from grounding clamp. This was solved by grounding the workpiece in four places.My welding equipment is Motoman SK-6R with MRC controller, and OTC Turbo Pulse 350 welder.
I hope this helps.