PAPER ENGLISH

TECHNOLOGY WELDING ROBOT

Name : Efendi Wahyu Irianto

NIM : 15/384676/SV/09033
Class : EM5

DEPARTEMEN TEKNIK MESIN

SEKOLAH VOKASI
UNIVERSITAS GADJAH MADA
YOGYAKARTA
2017
 WELDING ROBOT

A robot is a machine especially one programmable by a computer capable of carrying

out a complex series of actions automatically. Robots can be guided by an external control device
or the control may be embedded within. Robots may be constructed to take on human form but
most robots are machines designed to perform a task with no regard to how they look. Robots are
made with the purpose to help human work.

Robots have replaced humans in performing repetitive and dangerous tasks which
humans prefer not to do, or are unable to do because of size limitations, or which take place in
extreme environments such as outer space or the bottom of the sea. There are concerns about the
increasing use of robots and their role in society. Robots are blamed for rising technological
unemployment as they replace workers in increasing numbers of functions. The use of robots in
military combat raises ethical concerns. The possibilities of robot autonomy and potential
repercussions have been addressed in fiction and may be a realistic concern in the future. The
function of robots in the industrial field is generally intended to replace the human role in
performing tasks that require a large / strong force, which requires high accuracy and high risk to
human safety. So, the robot can minimize human error (human error) on the process of
industrialization and can increase productivity of production in an efficient manner that provides
more benefits.

Robots can also be used continuously without feeling any boredom in the production and
can also be used in a very dangerous environment. For example in the nuclear industry, robots are
used because nuclear radiation is very dangerous for humans if humans are within a radius or a
distance close enough to the area. Robots are also used in assembly, welding, smelting, painting
and machining industries. Industrial robots can be a solution to high production levels because
they can be operated continuously, flexibly programmable that is reliable in reliability compared
to humans and allows to be connected with other control devices such as PLCs, computers and
others.

Definition of robot arc welding is is the use of mechanized programmable tools (robots),
which completely automate a welding process by both performing the weld and handling the part.
Processes such as gas metal arc welding, while often automated, are not necessarily equivalent to
robot welding, since a human operator sometimes prepares the materials to be welded. Robot
welding is a relatively new application of robotics, even though robots were first introduced into
US industry during the 1960s. The use of robots in welding did not take off until the 1980s, when
the automotive industry began using robots extensively for spot welding. Since then, both the
number of robots used in industry and the number of their applications has grown greatly. In 2005,
more than 120,000 robots were in use in North American industry, about half of them for welding.
Growth is primarily limited by high equipment costs, and the resulting restriction to high-
production applications.
 Robot arc welding has begun growing quickly just recently, and already it commands about
20% of industrial robot applications. The major components of arc welding robots are the
manipulator or the mechanical unit and the controller, which acts as the robot's "brain". The
manipulator is what makes the robot move, and the design of these systems can be categorized into
several common types, such as SCARA and cartesian coordinate robot, which use different
coordinate systems to direct the arms of the machine.

The robot may weld a pre-programmed position, be guided by machine vision, or by a combination
of the two methods. However, the many benefits of robotic welding have proven to make it a
technology that helps many original equipment manufacturers increase accuracy, repeat-ability,
and throughput

Robot welding is commonly used for resistance spot welding and arc welding in high
production applications, such as the automotive industry. Welding robot is now widely developed
and used in various companies. There are several advantages to using a robot for a class. Weld
robots work productively because they can work without rest or holiday. Robots are also more
consistent and thorough. Here are three main benefits of welding robot. Robot welding means
welding that is performed and controlled by robotic equipment. In general equipment for automatic
arc welding is designed differently from that used for manual arc welding. Automatic arc welding
normally involves high duty cycles, and the welding equipment must be able to operate under those
conditions. In addition, the equipment components must have the necessary features and controls
to interface with the main control system.

A special kind of electrical power is required to make an arc weld. The special power is provided
by a welding machine, also known as a power source. All arc welding processes use an arc welding
gun or torch to transmit welding current from a welding cable to the electrode. They also provide
for shielding the weld area from the atmosphere. The nozzle of the torch is close to the arc and
will gradually pick up spatter. A torch cleaner (normally automatic) is often used in robot arc
welding systems to remove the spatter. All of the continous electrode wire arc processes require
an electrode feeder to feed the consumable electrode wire into the arc. Welding fixtures and
workpiece manipulators hold and position parts to ensure precise welding by the robot. The
productivity of the robot welding cell is speeded up by having an automatically rotating or
switching fixture, so that the operator can be fixing one set of parts while the robot is welding
another.To be able to guarantee that the electrode tip and the tool frame are accurately known with
respect to each other, the calibration process of the TCP (Tool Center Point) is important. An
automatic TCP calibration device facilitates this time consuming task.

As one of the big companies, PT. ASTRA HONDA MOTOR annually produces hundreds
of thousands of motorcycles for one vehicle brand and employs hundreds of employees. To
improve production and work efficiency, PT. ASTRA HONDA MOTOR uses a lot of equipment
and modern machinery like in other modern companies. One of them is Arc Welding Robot.

In an effort to increase high productivity, a company will strive to streamline and maximize
its potential resources, as well as reduce unnecessary costs. The way commonly used in the modern
era like this is the automation of production processes with the use of tools that are completely
automated and controlled. The advantages of using such tools are fast, accurate, and operating
costs are relatively cheap compared to using human labor. PT. ASTRA HONDA MOTOR has
implemented the use of modern and automated machines in its production process.

In the case of installing Arc Welding Robot basically been programmed to be directly used
in industrial processes, but did not rule out if the application there is an additional support interface
so for this interest we can still edit the existing program. With the ease of this robot has been
supported PLC system then the operator can access it simply using diargam ladder (ladder
diagram). As for the use of the welding process itself we no longer need to bother access to its
PLC, because for use we will only set welding parameters such as: welding line coordinates,
currents, voltages, welding speed, wire length, welding type as well as the type of robot movement
associated with axis-axis. All program inputs can be accessed through a tool called teach pendant,
with this tool we are able to write welding program then can be saved for further usage.

Arc Welding Robot used in PT. ASTRA HONDA MOTOR at Sunter Plant works to weld
on a motorized part of welding scope for Frame body and arm swing motor which utilizes
automation in welding process, accuracy and efficiency in the work process so that the resulting
process is faster and smoother. Robot welding process is assisted by servo motor as a driver and
can be controlled and then programmed through the teach pendant.

Benefits of using welding robots :

1. Saving time
The robotic welding system does its job quickly. The welding robot does slightly less than
manual welding. Unlike humans, robots do not have to rest, vacation and others. Work can
continue uninterruptedly, 24 hours a day. This makes the company more productive.

2. Save money
The cost of manual welding can be expensive. This is because welding requires time, skill
and concentration. Besides this work is also dangerous. Welding is a dangerous job.
Flashes of light, light sparks, smoke and manual welding heat become energy-draining and
dangerous jobs. Welding robots can save on costs and job protection for high-risk welding
parts.

3. Save material
The most important welders can also make mistakes. Will the new, old welding robots,
everything can be adjusted including energy and electricity usage. The welding robot is
energy efficient because it does the job consistently. The accuracy and consistency of this
robot means welding material and time saved. Of course the quality or welding results
remain good.