Welding Technology
Overview
Welding, also known as fusion welding, is a manufacturing process that joins metals or other thermoplastic materials such as plastics through heating, high temperature, or high pressure. As an important manufacturing technology, welding plays an irreplaceable role in modern industry. As science and technology continue to advance and welding techniques keep innovating, welding technology will be applied and promoted in more and more fields.
For a detailed introduction to welding processes, please refer to: Metal Welding Industry Solution
For a detailed introduction to welding highlights and operating procedures, please refer to: Welding Industry Solution Manual
Welding Highlights
Fast Arc Start / Arc End Technology
● If the crater is not completely filled during arc start/end or the current decay time is too short, the small amount of deposited metal at the arc-end location can cause concavities. These weak spots are prone to micro-cracks at the arc-end location under transformation stress and restraint stress. ● By optimizing the welding logic, iNexBot enables the system to prepare the welding machine for arc start in advance — using early gas pre-flow, slow wire feed, and current/voltage adjustment — so that the arc ignites immediately when the robot reaches the arc-start point. This avoids hesitation and delay, improves production cycle time, shortens arc-start time, raises the arc-start success rate, and improves weld quality. ● At arc end, gradual current/voltage ramping and delayed gas flow prevent cratering and wire sticking. If sticking occurs, a preset command can be executed to break the weld wire free. ● When re-arc starting after arc end, the system remembers the last arc-extinguishing point and automatically adjusts the wire feed speed and length for arc start, improving the arc-start success rate.
Robot End-Effector Anti-Vibration Technology
● Welding robots demand high cycle times; therefore, welding cycle time is a very important factor in welding production. ● Analysis across multiple projects shows that welding speed is constrained by the welding process and difficult to adjust. As a result, the robot's air-cut (non-welding) travel speed becomes the most effective means of improving welding cycle time. ● Using motion planning based on quintic polynomials, iNexBot achieves smooth velocity/acceleration transitions, fully unlocking the robot's motion capability while ensuring safety. ● Aggressive acceleration/deceleration can easily cause vibration at the torch tip, affecting the accuracy of the arc-start point and, in extreme cases, even causing collisions that damage the torch. By applying dynamics and torque feedforward technology, iNexBot provides high-speed vibration suppression that effectively improves the motion quality of welding robots.
Multi-Layer Multi-Pass Welding
● Multi-layer multi-pass welding divides the weld into multiple layers, each layer into multiple passes, and welds layer by layer, pass by pass in a defined sequence. This function is intended for large, deep welds: it reduces heat input and distortion and lowers the defect rate. It suits a wide range of weld types, including butt, fillet, and plug welds. ● iNexBot adds a multi-layer multi-pass function module to the process section to store multi-layer multi-pass parameters, along with two new commands: multi-layer multi-pass offset start and multi-layer multi-pass offset end. Multi-layer multi-pass welding is realized through configured process parameters and preset job files. In addition, the new control system version improves the multi-layer multi-pass process by adding head/tail retraction, push angle, and tilt angle settings, making it more flexible and easier to use (this feature is subject to the specific release version).
External-Axis Coordinated Weave Welding
● External-axis coordinated weave welding means that during welding, external axes assist in repositioning or shifting the workpiece so that the welding robot can weld at the optimal angle and posture. ● The new iNexBot control system enables coordinated weave welding between external axes and the robot through external-axis parameter adjustment and enabling of the coordination function. Precise external-axis control ensures that the welding robot welds in the best position and posture, improving welding accuracy.
Arc-Start Ramping Optimization
● Arc-start ramping refers to the process at the beginning of welding in which parameters such as welding current and voltage gradually transition from their initial state to a stable welding state. This process helps the welding arc form stably and the welding proceed smoothly. ● In the new iNexBot control system, arc-start ramping has been optimized: by setting arc-start parameters, enabling arc-start ramping, and setting the ramp time, users can precisely adjust the current, voltage, and time parameters. This helps ensure a smooth start to the welding process, reduces impact/damage to the workpiece caused by abrupt parameter changes, and effectively improves welding stability.
The Most Powerful Positioner Coordination System
● iNexBot's positioner coordination system supports up to 5 external axes with excellent scalability.
Key Features
● Arc welding dedicated commands: compatible with Yaskawa ARCON/ARCOFF/ARCSET commands
● Open communication protocol with multi-brand welding machine adaptation: Fronius, Aotai, Megmeet, Mejanick, Riland, EWM, etc.
● Supports multiple groups of welding process parameters for flexible on-site invocation
● Arc-break/arc-extinguish wire retraction prevents wire sticking
● Arc-break restart and breakpoint resume
● Simulated multi-segment welding machine matching
● Flying arc start
● Weave welding: sine weave, Z weave, L weave, figure-8 weave, circular weave, external-axis fixed-point weave
● Fish-scale welding process
● Multi-layer multi-pass welding process
● Arc-start and arc-end ramping; real-time current/voltage adjustment during welding
● Intelligent recommendation of suitable current and voltage based on the selected plate material
Success Stories
Oversized Weld Head at Arc Start? Easily Solved!
Problem Analysis
● Symptom: the customer reported that the weld head was significantly larger than at other weld locations, affecting the overall appearance of the weld.
● Root Cause: after careful inspection by iNexBot's on-site application engineers, the root cause was found to be that the torch lingered too long at the arc-start point, melting excessive weld wire and forming an oversized weld head.
Solution
● On-Site Service: iNexBot responded quickly, dispatching professional on-site application engineers to the customer's site, where they identified the root cause through on-site inspection and diagnosis.
● Technical Innovation: to address the problem, iNexBot's teams worked diligently to develop and add arc-start parameter settings to the welding equipment configuration interface. These parameters include, but are not limited to, arc detection time, arc detection confirmation time, and arc depletion detection time, allowing users to fine-tune them according to specific welding needs.
● Results Verification: after applying the new parameters, the oversized weld head problem improved significantly, welding quality noticeably improved, and the customer's expectations were met — the customer expressed great satisfaction.
Real-Time Data Fine-Tuning Improves Welding Tolerance
Problem Analysis
● Symptom: the customer reported inconsistent weld lengths, which prevented achieving the desired finished weld quality.
● Root Cause: iNexBot's applications and testing departments first conducted an in-depth analysis of real-time data during welding and, combined with the actual weld geometry, identified the key factor causing inconsistent weld lengths: process parameters kept changing during welding — especially current and voltage variations, which caused instability and affected the weld quality.
Solution
● On-Site Service: after detailed communication with on-site personnel at the customer's facility, iNexBot's on-site application engineers identified the problem and provided real-time feedback.
● Technical Innovation: based on the real-time data analysis, iNexBot added a fine-tuning function for arc-related parameters to the welding equipment configuration interface, enabling per-weld current/voltage adjustment: fine-tuning the current ensures stable heat output during welding, and fine-tuning the voltage matches the wire melting rate so that the wire melts evenly and forms a uniform weld with the base material.
● Results Verification: after using the fine-tuning function, the inconsistent weld length problem improved considerably and welding tolerance increased. The customer reported a higher yield rate, effectively safeguarding product quality.
Future Outlook
As the era of intelligent manufacturing arrives, iNexBot will deeply integrate advanced information technology, artificial intelligence, and automation technology to drive the intelligent upgrade of welding processes and equipment. We are committed to developing more efficient and more precise welding solutions to meet the market's urgent demand for high-quality, high-efficiency production.
At the same time, iNexBot keeps a close eye on cutting-edge industry trends, actively responds to the challenges and opportunities of new processes, and continues to expand the boundaries of welding technology applications. While deepening its presence in the domestic market, iNexBot is also looking to the global stage, seeking international cooperation and exchange to bring China's outstanding welding technology achievements to the world. Moving forward, iNexBot never stops progressing.
