Top 5 Robotic Welder Challenges

When we talk about robotic welder challenges, we are more specifically talking about the programming behind it. Robotic welding has mostly been used to high production applications because it is such a lengthy and complicated process to program any changes in product lines. To even set up any kind of robotic welding equipment, you need to have a vast amount of knowledge on this area and even then robot welding programming and all the steps and methods it takes, do not come second nature to most programmers.

Below we will go over the most common robotic welder programming challenges and errors so you can gain a better understanding on what may be causing you problems and what challenges this technology may present to you.

1. Stick with the same manufacturer and model

The first problem that most people seem to make when it comes to robotic welding and the programming behind it, is that they forget all programming tools from different robot manufacturers, and any control systems for robots always vary a little from manufacturer to manufacturer and there is always a difference in models. This is a common problem when someone thinks they can get the same effect by using a similar part that is not part for that model or program. It is important to remember that just because something might work for someone else does not necessarily mean it will work for you.

2. Path plan and trajectory

When working with a robotic welder for the first time, most programmers are unsure what parts of the robot links need to be programmed. In an ideal world, just programming the tip of the arm or the base position would make things a whole lot easier, unfortunately, most programmers need to remember to program the path plan and trajectory of each link. Each link must be programmed as the arcs and joint angles must be able to work and function properly.

3. Acceleration and Deceleration

As well as planning out and programming the path plan and trajectory of each link, there is another aspect of the joints that must be remembered that most forget and that is to designate acceleration and deceleration of each link. Each joint must be programmed with a specific amount of acceleration and deceleration in order for the speed and coordination of each movement to function and work the way it’s supposed to.

4. Inputs and outputs

I think that the main theme here is to remember all the different parts that make up robotic welders and to remember that each of these parts requires a certain amount of programming. The next part that you should always remember is to define sensor inputs and outputs. This is additional programming that you must learn so that the robot can use these sensors for inputs and outputs and use a binary signal to be able to select robot programs so the robot can perform any specific actions and movements.

5. Practice makes perfect

The last but most important thing to remember is that anyone who is working with this kind of technology should be properly trained and the experience can only be gained through trial and error. Do not let yourself get discouraged if you are not successful the first few times, this is something that usually takes years to master and a lot of trial and error in application.