Posts by keyboard7

Have you checked the physical conditions of the e stops in question?

The one on the panel need to be twisted to be released. the external need to be manually pulled up

to be released. I have had to drive back to work after my shift to find out that one or both of these were not released after A barrel of wire was changed. I now ask for faults when I get these calls.

The hand broken could be the torch being rotated out of the correct position.

there is A green light on the cable that lights up when it is rotated into the right position.

These are just things that I look for first now, as I have spent lots of time in the past not knowing where to start with trouble shooting.

Have been working with MIG welding robots for 20 years.

The easy welds are easy, the hard ones can be very difficult to get right every time.

You may want to create A new schedule for this weld you are having issues with.

Some of my programs use 10 or 12 different weld schedules for different types of welds.

That is normally done on the welding power source, you select the process you want.

There is normally several to choose from. If you stick with pulse, you can adjust the heat with the trim

setting.

If you are using pulse welding, you can also adjust the trim to get finer weld adjustments.

You can increase the weld speed inches per minute. This will allow for A larger bead to be deposited

without burning thru your material. I would try that first. If it only happens in one or a couple of spots,

Copper or brass inserts can be put under the welds in your Jig.

Make sure the welding wire is not stuck by feeding it with the teach pendant, reset the fault on the teach pendant. Should be good to go.

Not sure if you meant function key or not, but that is where you change the group.

Hit function, then change group.

The wire cast is A great point! We always keep A very close wire stick out for our mig welding robots.

This may mean A little more time spent cleaning the tip and nozzle, but much higher quality of welds.

Depending on how much weld is deposited on each cycle, the tip needs to be changed at regular intervals. The wire feeding thru the tip at high wire speed settings wears them out causing the hole the wire travels thru to enlarge, giving the wire more chance to miss optimum location with long wire stick out. Have seen many times where the tip had not been changed for A long time because it was still working fine according to the operator, even though they complained of poor weld quality.

Always remember to put in A brand new tip and make sure it is tight before doing any touch ups on welds.

This is always the question when dealing with welds moving around. First thing I would do is make sure all the mounting bolts are tight on both the robot, and the fixturing. You can then teach A point in A small program to touch the wire in A spot on the fixture. Try running the program A few times to see if the wire goes to the same spot every time. I have found most of the time that it is the fixturing or the material that will vary. You could use A laser tracker to check the positions of the robot, and the material you wish to weld. Set it up in the cell and step thru the program to see if the robot and fixture repeat cycle after cycle. More information on your process when you post will also help members to help you with solutions they may have come up with.

Wire mesh, you can google it. Comes in different size wire diameters, and different size square openings.

If you find the right source, they can make panels to whatever size you want.

Picture A piece of window screen, with thicker wire, and bigger openings.

The size we use is .100" diam wire, with 2" square openings.

if you google RS232 port, you will see an adapter that A flash drive card will fit into.

You can use this to make your backup onto the flash drive. any card reader that will accept A flash drive card will let you load A back up to your computer.

You can searce memory backup on this forum for more details on the steps required on the teach pendant.

Does your controller have the slot for 32 pin card adapter?

To Zsalonek,

We tried, but the expanded metal bonds would not be in the same places on each piece. We switched to wire mesh, the wires were more consistent with this material.

The welding was mostly in straight lines x and y, and this also sped up the cycle times by almost half.

Don't know if this will work for you application or if it is even an option, but it worked for us.

You can order grease kits from Lincoln Electric. Order kits for each robot you want to grease.

Each kit will come with instructions on ports that need to be open and where to add the grease.

They will also tell you what position the arm needs to be in when adding grease.

They will send you the grease that is reccomended for your specific robot.

This can be A messy job, wear coveralls, or better yet have someone else do it.

Lincoln Electric sells these parts. Tell them your robot arm information and they will help you.

We get all our spare parts from them. Get a spare switch and change that out also.

Both these parts wear out at the same time.

Dont Know if this is A new program or not. When writing A new program with A cell that has 3 groups, the group mask must be set up
Before you start programing. That way only the robot, group 1, and either group 2 or 3 will be recording points. The other group turning,
May be because side B was moved sometime during the programing and now it is in the program as A recorder point.
You may have to start all over again because this point will be recorded in your program from when ever the other table was moved.

You need to be very careful when attempting this for the first time. We order A kit from Lincoln for our specific robots.
There are detailed instructions for how the arm is positioned for each axis when being greased. There is normally an outlet that need to be open when adding grease, or the seal will be damaged. This is A costly repair. The kit comes with the recomended grease, And applicators
to add the grease. This may be slower, but we have never had damage occur during this process. Do A little research before you have someone attempt this for the first time.

Many times this is caused by not having the wire feed speed or trim if pulse welding or the volts not set within the parameters in the weld schedule. Go to the weld schedule screen, check which weld is giving you the error, and adjust the wire, trim, or volts.
Which weld process are you using?

What process are you trying to preform? Sometimes you can add a point in the center between the corners of the square.
You may need to play with the location of this point in or out to get the results you are looking for. Use CNT 100.

in the instruction screen curser down to weave sine instruction, then press F4 choice to select a new weave pattern from the sub menu, then enter. There are options to choose from there. Once selected this weave will be called when weave start is used after arc start.