ComArc Sensing and Weaving

Grettings !

Im having some trouble with a certain project.

The assembly of the tank varries a lot and we are having trouble programming the weld path without any sensors.

Here is an image of the Slanted pipe on top of the tank we are having most difficulty with. The position of the pipe varies quite a lot ( up to 5 mm).

Link : https://imgur.com/a/slanted-pipe-Zabahs4

We have ComArc and Touch Sense ( through wire), but i have 0 experience in using them ( everything i learned so far is what i found in the respected pdfs).

As far as ComArc sensor goes, it needs to have a weaving pattern for dettecting the seam. Now because the pipe is slanted the angle changes over distance so can we even use the comarc sensor here since the distance of Wire - Pipe changes as the torch goes around ?

Would i be able to use ComArc sensor if i used WeaveAdjust instruction that lets you change the weaving over a distance ? how accurate would that then be ?

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Im thinking maybe a better solution would be if we used Touch Sense on 3 or 4 points of the pipe to get the exact position, and then shift the pipe position/weld path based on that ?

Any ideas/suggestions are appreciated!

Thank you for your time and replies !

I managed to set up the Comarc sensor. It holds the seam well, the problem im having is it does undercuts into the bottom plate of our T weld.

I have measured the phase compensation value and entered it into the parameters.

The pdfs states :

To lengthen a wire extension, decrease the UP/DOWN
(U/D) correction condition in units of 10 A.
• To shorten a wire extension, increase the UP/DOWN (U/
D) correction condition in units of 10 A.
• To move the targeted position toward the wall, decrease
the LEFT/RIGHT (L/R) correction condition in units of 5
A.
• To move the targeted position toward the horizontal
direction, increase the LEFT/RIGHT (L/R) correction
condition in units of 5 A.

My current U/D correction is set at 180 amps. IF i increase it to 190 or 200, the torch moves even more towards the plate untill i start getting Shock sensor overrun alarm ( torch smashes into the bottom plate ).

If i decrease the U/D correction ( tried going to 160amps) it still does undercuts.....

Is the problem maybe with our weave ( the taught path when doing measurments for comarc was maybe poorly done and it already did undercuts there, so we basically taught our robot how to do undercuts ?)

But wouldnt changing the U/D parameters then remove the undercut ?

Here are some pictures of the problem : https://imgur.com/a/comarc-undercut-problems-KGHnfz6

Any help is appreciated.

The problem was our welding and weawing parameters were not set up properly for what we were trying to do. I set up new Weld parameters and adjusted the weaving, now it welds without undercuts and keeps the Seam.

Another problem we are having though is a Slanted Pipe ( angle of pipe changes) and the comarc starts to drift upwards as the angle opens up. It cut our Pipe in half basically.

Here is a picture. https://imgur.com/a/IdoZl8C ( use of comarc - it drifts and cuts pipe in half)

A picture without using comarc https://imgur.com/a/slanted-pipe-Zabahs4,

jarm Hey ! I already started playing with the problem and you are right, the secret is in torch angle and weaving in general. With a faster frequency it tracks way better and it doesnt loose track as much.

We also used Short circuit spray instead of pulse ( less chance of burnthrough ) since if the burnthrough happened the sensor would loose its track.

With some more minor adjustments im certain we will be able to weld the slanted pipe without any problems, otherwise ill make a touchsense program to touch up the pipe and get its exact position for better positioning the weld seam for each pipe.